Induction heating system, induction heating method, output monitoring apparatus, output monitoring method, and induction heating apparatus

ABSTRACT

An induction heating system includes induction heating apparatuses, each including a high-frequency current transformer, a low-frequency current transformer and a heating coil, a high-frequency input switch connected to the high-frequency current transformer, a low-frequency input switch connected to the low-frequency current transformer, a first power source to output a high-frequency electric power and a low frequency electric power, a second power source, a first power source output switch connectable to the first power source, a second power source output switch connectable to the second power source, and a switch controller. Each induction heating apparatus includes a heater controller to send a signal to the switching controller to turn on one of the first power source output switch and the second power source output switch, to turn off the other, and to switch on or off each of the high-frequency input switch and the low-frequency input switch.

TECHNICAL FIELD

The present invention relates to an induction heating system and aninduction heating method for supplying electric power with differentfrequencies to a plurality of induction heating apparatuses, an outputmonitoring apparatus and an output monitoring method for monitoring anoutput situation when electric power is supplied from a power supplyapparatus to a heating coil to perform induction heating, and aninduction heating apparatus having a low-frequency current transformerand a high-frequency current transformer.

BACKGROUND ART

In a system according to a first related art, in order to performinduction heating on a workpiece according to the shape of the workpieceor a portion of the workpiece to be heated, or according to dispositionof a coil with respect to the workpiece, a workpiece supporting manner,or the like, different types of multiple induction heating apparatusesare disposed. For example, when induction heating is performed, thepenetration depth of a magnetic flux, which is generated from a heatingcoil, from the outer surface of a workpiece into the workpiece dependson a frequency, according to the thickness of a heat treatment layer, afrequency is selected. In order to thicken the heat treatment layer, alow frequency is used, and in order to make the heat treatment layershallow, a high frequency is used. To this end, there is a systemconfigured by disposing power sources having different outputfrequencies and connecting the power sources to induction heatingapparatuses through switches, respectively, to perform induction heatingon workpieces by the different frequencies (see, e.g., JP60-249288A).

Further, recently, induction heating has been performed using aplurality of frequencies, not one frequency. For example, inductionheating has been performed by superimposing a low frequency and a highfrequency at the same time.

However, if a power supply system for outputting electric power of aplurality of frequencies is disposed with respect to one inductionheating apparatus, equipment becomes large in scale, and an inductionheating system becomes expensive. Also, in the system disclosed inJP60-249288A, it is impossible to attach heating coils different inshape or size in the induction heating apparatuses, and freely set atime chart of power supply to each heating coil. Further, if it isassumed to make the thickness of the heat treatment layer different foreach workpiece or to perform various heat treatments such as quenchingand tempering in the individual induction heating apparatuses, sinceload impedances including workpieces are different with respect to thepower supply system, it is necessary to provide a large-scale powersupply system or matching circuit, and thus the entire induction heatingsystem becomes large-scale.

In a system according to a second related art, one power supplyapparatus is used to supply electric power to a plurality of inductionheating apparatuses. This system includes, for example, a high-frequencypower source, a current transformer having the primary side connected tothe high-frequency power source, and a plurality of induction heatingcoils connected in parallel to the secondary side of the currenttransformer (see, e.g., JP2009-158394A). In this system, a voltagedetecting sensor is provided on the secondary side of the currenttransformer, and a current detecting sensor is provided at a positionadjacent to the induction heating coils. On the basis of the value of avoltage which the voltage detecting sensor detects, and the value of acurrent which the current detecting sensor detects, the magnitude ofelectric power being supplied to the induction heating coils ismonitored.

However, when the power supply apparatus outputs electric power by atime-division multiplexing method or a superimposing method, it isimpossible to monitor the output situation. Also, in a case where aplurality of power supply apparatuses supplies electric power accordingto a supply condition requested by each induction heating apparatus,there is no method of confirming whether electric power is beingsupplied according to the supply condition.

SUMMARY OF INVENTION

An object of the present invention is to provide an induction heatingsystem and method capable of supplying electric power from a singlepower source system to a plurality of induction heating apparatuses andfreely setting a time chart of power supply to each induction heatingapparatus.

Another object of the present invention is to provide an outputmonitoring apparatus and an output monitoring method capable of graspingan output situation from a power supply apparatus. Another object of thepresent invention is to provide an induction heating system having thatoutput monitoring apparatus. Another object of the present invention isto provide an output monitoring apparatus and method and an inductionheating system capable of monitoring whether electric power is beingsupplied according to a supply condition by an instruction of aninduction heating apparatus.

Another object of the present invention is to provide an inductionheating apparatus which requires a smaller space to arrange and canperform induction heating with flexibility as one of a plurality ofinduction heating apparatuses forming an induction heating system.

According to an aspect of the present invention, an induction heatingsystem includes a plurality of induction heating apparatuses, each ofthe induction heating apparatuses including a high-frequency currenttransformer, a low-frequency current transformer, and a heating coil towhich a secondary side of the high-frequency current transformer and asecondary side of the low-frequency current transformer are connected inparallel, a high-frequency input switch connected to a primary side ofthe high-frequency current transformer, a low-frequency input switchconnected to a primary side of the low-frequency current transformer, afirst power source configured to adjust a ratio of a high frequencyoutput time and a low frequency output time with respect to an outputperiod and to output a high-frequency electric power and a low frequencyelectric power, a second power source configured to output an electricpower of a frequency that is different from a frequency of the electricpower output from the first power source, a first power source outputswitch arranged to be connectable to a low-frequency output terminal ofthe first power source, a second power source output switch arranged tobe connectable to an output terminal of the second power source, and aswitch controller configured to control the high-frequency input switchand the low-frequency input switch for each of the induction heatingapparatuses and to control the first power source output switch and thesecond power source output switch so as to connect at least one of theinduction heating apparatuses to at least one of the first power sourceand the second power source. Each of the induction heating apparatusesfurther includes a heater controller configured to send a switchingrequest signal to the switching controller to turn on one of the firstpower source output switch and the second power source output switch, toturn off the other of the first power source output switch and thesecond power source output switch, and to switch on or off each of thehigh-frequency input switch and the low-frequency input switch.

Upon receipt of the switching request signal, the switching controllercontrols the first power source output switch and the second powersource output switch and also the high-frequency input switch and thelow-frequency input switch that are connected to the induction heatingapparatus from which the switching request signal is sent. The switchingcontroller sends a switching completion signal to the induction heatingapparatus when the switching controller has completed the control inaccordance with the switching request signal. Upon receipt of theswitching completion signal, the induction heating apparatus controls anoutput of the first power source and an output of the second powersource.

According to another aspects of the present invention, an inductionheating method includes providing a plurality of induction heatingapparatuses each having a heating coil, a first power source configuredto adjust a ratio of a high frequency output time and a low frequencyoutput time with respect to an output period and to output ahigh-frequency electric power and a low frequency electric power, asecond power source configured to output an electric power of afrequency that is different from a frequency of the electric poweroutput from the first power source, and a switching section, operatingthe switching section from one of the induction heating apparatuses toselect one of a first mode, a second mode, a third mode, and a fourthmode, and induction heating a workpiece arranged on the one of theinduction heating apparatuses. In the first mode, the one of theinduction heating apparatuses receives one of the high-frequencyelectric power and the low frequency electric power from the first powersource. In the second mode, the one of the induction heating apparatusesreceives the electric power from the second power source. In the thirdmode, the one of the induction heating apparatuses receives electricpower of different frequencies from the first power source by atime-division method. In the fourth mode, the one of the inductionheating apparatuses receives one of the high-frequency electric powerand the low frequency electric power from the first power source and theelectric power from the second power source in a superimposed manner.

According to the above aspects of the present invention, the powersource system is configured to output a plurality of frequencies. Thepower source system can output, to the induction heating apparatuses,the high frequency and the low frequency simultaneously or alternately.Therefore, the ratio of the high frequency component and the lowfrequency component of the electric power supplied form the power sourcesystem to the induction heating apparatuses can be set optionally.Accordingly, when the output frequencies from the power source systemare f1, f2 and f3, the effect (hereinafter, the “frequency effect”)equivalent to a case in which an induction heating is performed with afrequency other than f1, f2 and f3 can be provided. Further, because theplurality of induction heating apparatuses are supplied with power froma single power source system, it is possible to downsize the system.

According to another aspect of the present invention, an outputmonitoring apparatus is adapted to be attached to one or more powersupply apparatuses, each power supply apparatus including a converterconfigured to convert an alternate current into a direct current and aninverter configured to switch on and off, at an given frequency, thedirect current input from the converter, the power supply apparatusbeing adapted to be connected to a single heating coil to supply powerto the single heating coil. The output monitoring apparatus includes ameasuring section configured to measure, at each sampling time, acurrent and a voltage of the direct current output from the converter tothe inverter, and a processing unit configured to obtain an amount ofelectric power for each frequency from values of the current and thevoltage measured at each sampling time by the measuring section, and toobtain an average electric power for each frequency based on the amountof electric power for each frequency.

The measuring section may include a current and voltage measuring unitconfigured to measure, at each sampling time, the current and thevoltage of the direct current output from the converter to the inverter,and a frequency measuring unit configured to count the number of timesof switching made by the inverter per unit time. The processing unitobtains the amount of electric power for each frequency from the valuesof the current and the voltage measured at each sampling time by thecurrent and voltage measuring unit, and obtains the average electricpower for each frequency based on the amount of electric power for eachfrequency

The inverter may supply an output electric power of a high frequency andan output electric power of a low frequency from one of the power supplyapparatuses to the single heating coil by time-division multiplexing byadjusting a ratio of a high frequency output time and a low frequencyoutput time with respect to an output period. The processing unitobtains the average electric power for each of the high frequency andthe low frequency output from the one of the power supply apparatusesbased on values measure by the measuring section.

The one or more power supply apparatuses may include a first powersupply apparatus and a second power supply apparatus, wherein theinverter of the first power supply apparatus switches on and off, at afirst frequency, the direct current input from the converter of thefirst power supply apparatus, the inverter of the second power supplyapparatus switches on and off, at a second frequency, the direct currentinput from the converter of the second power supply apparatus, whereinthe electric power from the first and second power supply apparatuses tothe single heating coil by superimposing the first frequency and thesecond frequency. The measuring section includes a first measuring unitconfigured to measure, at each sampling time, a current and a voltage ofthe direct current output from the converter to the inverter in thefirst power supply apparatus, and a second measuring unit configured tomeasure, at each sampling time, a current and a voltage of the directcurrent output from the converter to the inverter in the second powersupply apparatus. The processing unit obtains the amount of electricpower for the first frequency from the current and the voltage measuredat each sampling time by the first measuring unit, the amount ofelectric power for the second frequency from the current and the voltagemeasured at each sampling time by the second measuring unit, and theaverage electric power for each frequency based on the amount ofelectric power for each frequency.

The power supply apparatus may be attached to a plurality of inductionheating apparatus, each having a single heating coil, via a switchingsection such that the power supply apparatus is connectable to any oneof the induction heating apparatuses by controlling the switchingsection from the plurality of induction heating apparatuses. Theprocessing unit is provided for each of the induction heatingapparatuses, and obtains the values measured by the measuring section todetermine the consistency between the average electric power of eachfrequency and a supply command sent to the power supply apparatus.

According to another aspect of the present invention, an inductionheating system includes a power supply apparatus having a converterconfigured to convert an alternate current into a direct current and aninverter configured to switch on and off, at an given frequency, thedirect current input from the converter, a plurality of inductionheating apparatuses, a switching section connected between the powersupply apparatus and the plurality of induction heating apparatuses tooutput an electric power supplied from the power supply apparatusselectively to one of the induction heating apparatuses, and an outputmonitoring apparatus having a measuring section configured to measure,at each sampling time, a current and a voltage of the direct currentoutput from the converter to the inverter, and a processing unitconfigured to obtain an amount of electric power for each frequency fromvalues of the current and the voltage measured at each sampling time bythe measuring section, and to obtain an average electric power for eachfrequency based on the amount of electric power for each frequency.

According to another aspect of the present invention, an inductionheating system includes a first power supply apparatus having aconverter configured to convert an alternate current into a directcurrent and an inverter configured to switch on and off, at a firstfrequency, the direct current input from the converter, a second powersupply apparatus having a converter configured to convert an alternatecurrent into a direct current and an inverter configured to switch onand off, at a second frequency, the direct current input from theconverter, a plurality of induction heating apparatuses, a switchingsection configured to selectively connect at least one of the firstpower supply apparatus and the second power supply apparatus to one ofthe induction heating apparatuses, and an output monitoring apparatushaving a measuring section configured to measure, at each sampling time,a current and a voltage of the direct current output from the converterto the inverter of each of the first power supply apparatus and thesecond power supply apparatus, and a processing unit configured toobtain an amount of electric power for each of the first frequency andthe second frequency from values of the current and the voltage measuredat each sampling time by the measuring section, and to obtain an averageelectric power for each of the first frequency and the second frequencybased on the amount of electric power for each of the first frequencyand the second frequency.

According to another aspect of the present invention, an outputmonitoring method includes measuring, at each sampling time, a currentand a voltage of one or more direct current that is being switched onand off at a plurality of frequencies to perform an induction heating,and obtaining an average electric power for each of the frequencies byadding up, at each sampling time, a product of the current and thevoltage that are measured while switching on and off at each of thefrequencies and by dividing the added products by an induction heatingtime, thereby monitoring an output electric power from the obtainedaverage electric power for each of the frequencies.

According to another aspect of the present invention, an outputmonitoring method includes measuring, at each sampling time, a currentand a voltage of a direct current that is being switched on and off at afirst frequency and a second frequency in a time-divided manner tooutput electric power of different frequencies to perform an inductionheating by time-division multiplexing, obtaining an average electricpower for the first frequency by adding up, at each sampling time, aproduct of the current and the voltage that are measured while switchingon and off at the first frequency and by dividing the added products byan induction heating time, obtaining an average electric power for thesecond frequency by adding up, at each sampling time, a product of thecurrent and the voltage that are measured while switching on and off atthe second frequency and by dividing the added products by an inductionheating time, and monitoring an output electric power from the obtainedaverage electric power for each of the first frequency and the secondfrequency.

The output monitoring method may further include monitoring an anomalyof a signal designating switching between the first frequency and thesecond frequency, based on whether a value of the average electric powerof the first frequency and a value of the average electric power of thesecond frequency change in time series.

According to another aspect of the present invention, an outputmonitoring method includes measuring, at each sampling time, a currentsand a voltage of a first direct current and a second direct currentwhile the first direct current is being switched on and off at a firstfrequency and the second direct current is being switched on and off ata second frequency in an alternating manner to perform an inductionheating, obtaining an average electric power for the first frequency byadding up, at each sampling time, a product of the current and thevoltage that are measured while switching on and off at the firstfrequency and by dividing the added products by an induction heatingtime, obtaining an average electric power for the second frequency byadding up, at each sampling time, a product of the current and thevoltage that are measured while switching on and off at the secondfrequency and by dividing the added products by an induction heatingtime, and monitoring an output electric power from the obtained averageelectric power for each of the first frequency and the second frequency.

According to another aspect of the present invention, an outputmonitoring method includes measuring, at each sampling time, a currentsand a voltage of a first direct current and a second direct currentwhile the first direct current is being switched on and off at a firstfrequency and the second direct current is being switched on and off ata second frequency and the first frequency and the second frequency arebeing superimposed to perform an induction heating, obtaining an averageelectric power for the first frequency by adding up, at each samplingtime, a product of the current and the voltage that are measured whileswitching on and off at the first frequency and by dividing the addedproducts by an induction heating time, obtaining an average electricpower for the second frequency by adding up, at each sampling time, aproduct of the current and the voltage that are measured while switchingon and off at the second frequency and by dividing the added products byan induction heating time, and monitoring an output electric power fromthe obtained average electric power for each of the first frequency andthe second frequency.

According to the aspects of the present invention described above, thecurrent and the voltage of the direct current before being switched onand off at the first frequency, the second frequency or other optionalfrequencies are measured at each sampling time, and the electric poweris obtained for each frequency from the values of the measured currentand voltage of the direct current in each sampling time. Therefore, itis possible to monitor the actually output electric power, which has notbeen realized in the past. Accordingly, even when an output is made bytime-division multiplex method or superimposing method using one or morepower supply apparatuses, the output condition can be monitored. Also,even when the frequency at which the direct current is switched on andoff is designated optionally, the actually output electric power can bemonitored. For example, even when one of the induction heatingapparatuses and the power supply apparatus are connected to supplyelectric power by controlling the power supply apparatus from theinduction heating apparatuses, and thereafter switching the inductionheating apparatus to be connected to the power supply apparatus, it ispossible to monitor whether the power supply apparatus is outputting theelectric power in line with the supply conditions instructed by theinduction heating apparatus.

According to another aspect of the present invention, an inductionheating apparatus includes a heating coil, and a low-frequency currenttransformer and a high-frequency current transformer that are connectedin the heating coil in parallel manner. The low-frequency currenttransformer includes a primary winding, a secondary winding, and a corecoupling the primary winding and the secondary winding. Thehigh-frequency current transformer includes a primary winding and asecondary winding. The low-frequency current transformer is arrangedbelow the high-frequency current transformer. The induction heatingapparatus may be configured such that the heating coil selected from aplurality of heating coils having different impedances is attachable,and such that the low-frequency current transformer selected from aplurality of low-frequency current transformers having different numberof turns of primary and secondary windings that satisfies an impedancematching condition corresponding to the heating coil is attachable.

The induction heating apparatus may further include a mounting framesupporting the low-frequency current transformer and the high-frequencycurrent transformer, and a replacing mechanism provided on the mountingframe to replace the low-frequency current transformer. The replacingmechanism includes a front-rear direction support extending in afront-rear direction of the mounting frame, and a carriage on which thelow-frequency current transformer is mounted and moves on the front-reardirection support. When the carriage is moved forward, the low-frequencycurrent transformer is arranged at a position at which the low-frequencycurrent transformer is connected to the heating coil. When the carriageis moved backward, the low-frequency current transformer is arranged ata position at which the low-frequency current transformer does notoverlap the high-frequency current transformer in a vertical direction.

The replacing mechanism may further include a base plate having atraveling surface for the carriage and supported on the front-reardirection support such that the base plate is displaceable in thefront-rear direction, front displacement means connecting the base plateand the mounting frame to displace the base plate forward with respectto the mounting frame, an inclined member arranged at a front end sideof the front-rear direction support such that a front end side of thebase plate is placed thereon and having a front-high inclination, and avertical displacement means arranged at a rear end side of the baseplate to displace the rear end side of the base plate in a verticaldirection with respect to the mounting frame. The vertical displacementmeans may displace the base plate forward to place the front end side ofthe base plate on the inclined member. The front displacement means andthe vertical displacement means may be arranged on the rear end side ofthe base plate.

According to the aspects of the present invention described above,because the low-frequency current transformer and the high-frequencycurrent transformer are arranged on top of one another, the arrangementspace is reduced and downsizing is possible. Further, because thelow-frequency current transformer has the core and therefore is heavierthan the high-frequency current transformer, by arranging thelow-frequency current transformer below the high-frequency currenttransformer, the gravity center of the apparatus is lowered, whereby theentire apparatus can be installed in a stable manner

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a view illustrating the configuration of an induction heatingsystem according to an embodiment of the present invention.

FIG. 2 is a view schematically illustrating a waveform which is outputfrom a first power source in FIG. 1.

FIG. 3 is a circuit diagram illustrating a circuit configuration betweena power source system and a heating coil in the induction heating systemshown in FIG. 1.

FIG. 4 is a circuit diagram illustrating another circuit configurationbetween the power source system and the heating coil in the inductionheating system shown in FIG. 1.

FIG. 5 is a view schematically illustrating signal waveforms which areoutput and controlled from the first power source shown in FIG. 3.

FIG. 6 is a side view schematically illustrating the arrangement andconfiguration of an induction heating apparatus shown in FIG. 1.

FIG. 7 is a side view schematically illustrating a lower supportingsection of the induction heating apparatus shown in FIG. 6.

FIG. 8A is a partial plan view illustrating the vicinities of the rearends of a carriage and a base plate in the induction heating apparatusshown in FIG. 6, and FIG. 8B is a partial side view illustrating thecarriage.

FIG. 9 is a partial rear view illustrating the vicinities of the rearends of the carriage and the base plate in the induction heatingapparatus shown in FIG. 6.

FIGS. 10A to 10C are partial side views illustrating the vicinities ofthe front ends of the carriage and the base plate in the inductionheating apparatus shown in FIG. 6. More specifically, FIG. 10A is a viewillustrating a situation in which a low-frequency current transformer isput on a mounting frame, FIG. 10B is a view illustrating a process oftransposing the low-frequency current transformer from the status ofFIG. 10A onto the carriage, and FIG. 10C is a view illustrating asituation where the low-frequency current transformer is mounted on acarriage plate and is taken out.

FIGS. 11A and 11B are a cross-sectional view and a plan viewillustrating a status where a high-frequency power supply path and alow-frequency power supply path are disposed on the frame of a duct,respectively.

FIGS. 12A and 12B are a plan view and a front view illustrating theconfiguration of each switch in the induction heating system of FIG. 1,respectively.

FIG. 13 is a view illustrating a sequence in which each inductionheating apparatus performs induction heating on a workpiece by theinduction heating system of FIG. 1, and shows a case where a firstinduction heating apparatus receives power supply from the first powersource by a time-division method, and performs induction heating.

FIG. 14 is a view illustrating a sequence in which each inductionheating apparatus performs induction heating on a workpiece by theinduction heating system of FIG. 1, and shows a case where the firstinduction heating apparatus receives power supply from the first powersource and a second power source by a superimposing method, and performsinduction heating.

FIG. 15 is a time chart illustrating how many induction heatingapparatuses one power source system can supply electric power to. InFIG. 15, (a) shows a case of using two induction heating apparatuses,(b) shows a case of using three induction heating apparatuses, and (c)shows a case of using five induction heating apparatuses.

FIGS. 16A to 16D are views illustrating examples of condition settingscreens which are used in a case of using each induction heatingapparatus to set a heating condition to a system control unit includinga switching controller. More specifically, FIG. 16A shows an example ofcondition settings of steps, FIG. 16B shows a first set table of thetime-division method, FIG. 16C shows a second set table of thetime-division method, and FIG. 16D is a first table of the superimposingmethod.

FIG. 17 is a view illustrating an example of an output monitoringscreen.

FIG. 18 is a view for explaining a first output monitoring method.

FIG. 19 is a view for explaining a second output monitoring method. InFIG. 19, (a) shows changes of a DC voltage and a DC current with time,and (b) to (e) show changes of a DT signal, integral low-frequency powerconsumption, integral high-frequency power consumption, and a heatsignal with time, respectively.

FIG. 20 is a block diagram illustrating the configuration of an outputmonitoring apparatus.

FIG. 21 is a view showing a case where electric power is supplied by thesuperimposing method and illustrating existence or non-existence of anoutput of a first frequency, and existence or non-existence of an outputof a second frequency in time series.

DESCRIPTION OF EMBODIMENTS

Hereinafter, an induction heating system according to an embodiment ofthe present invention will be described in detail with reference to thedrawings.

Overall Configuration of Induction Heating System

FIG. 1 is a view illustrating the configuration of an induction heatingsystem according to an embodiment of the present invention. As shown inFIG. 1, an induction heating system 1 according to an embodiment of thepresent invention includes a plurality of induction heating apparatuses10, a power source system 20 including a first power source 21 and asecond power source 26, and switching section 30 which are interposedbetween the power source system 20 and the induction heating apparatuses10 and switch connection between the power source system 20 and theinduction heating apparatuses 10. The switching section 30 include anoutput switch 31 for the first power source which is connected to thefirst power source 21, an output switch 32 for the second power sourcewhich is connected to the second power source 26, and high-frequencyinput switches 33 and low-frequency input switches 34 where areconnected to the input sides of the individual induction heatingapparatuses 10. In FIG. 1, three induction heating apparatuses 10 areshown. However, two, or four or more, or one induction heating apparatusmay be provided. Hereinafter, with respect to a case where threeinduction heating apparatuses are provided, the configuration of eachunit will be described.

Induction Heating Apparatus

In FIG. 1, as the induction heating apparatuses 10, first, second, andthird induction heating apparatuses 10A, 10B, and 10C are provided. Eachof the induction heating apparatuses 10 includes a high-frequencycurrent transformer 11, a low-frequency current transformer 12, aheating coil 13, and a heater controller 14.

Each of the high-frequency current transformers 11 and the low-frequencycurrent transformers 12 includes a primary winding and a secondarywinding. The turn ratio of each induction heating apparatus 10 dependson whether the induction heating apparatus is for a high frequency or alow frequency. Each of high-frequency current transformers 11 and thelow-frequency current transformers 12 may have a core such as an ironcore. Every high-frequency current transformer 11 may have an air core,not a core. Whether the high-frequency current transformers 11 havecores depends on the induction heating apparatuses 10. In other words,in at least one of the induction heating apparatuses 10 of the inductionheating system 1, the high-frequency current transformer 11 has an aircore, not a core, and the low-frequency current transformer 12 has acore.

In each of the high-frequency current transformers 11 and thelow-frequency current transformers 12, the secondary winding isconnected in parallel to the heating coil 13. Here, the shapes anddimensions of the heating coils 13 are selected according to workpiecesto be subjected to induction heating in the individual induction heatingapparatuses 10. Therefore, the impedances of the heating coils 13 dependon the heating coils 13.

Power Source System

The power source system 20 includes the first power source 21 and thesecond power source 26.

The first power source 21 changes the ratios of a high frequency outputtime and a low frequency output time with respect to an output period,and outputs electric power of different frequencies. The first powersource 21 alternately outputs a high frequency such as 200 kHz and a lowfrequency such as 10 kHz in a short time. The first power source 21adjusts the output ratio of the high frequency and the low frequency ina time (referred to as an output period) T, between 0% and 100%. FIG. 2is a view schematically illustrating a waveform which is output from thefirst power source 21. The horizontal axis represents time, and thevertical axis represents the duty ratio DT of the low frequency andoutput intensities. As shown in FIG. 2, in the output period T such as100 msec, in a time t_(L), the low frequency is output, and in a timet_(H), the high frequency is output. The duty ratio of the low frequencyis set to 100% in a case where only a low-frequency voltage or currentis output from the first power source 21 in the output period, and isset to 0% in a case where only a high-frequency voltage or current isoutput. The output period T is the sum of the time t_(L) and the timet_(H), and the ratio (tiff) of the time t_(L), when only the lowfrequency is output, with respect to the output period T will bereferred to as an output ratio, and the output ratio t_(L)/T can bearbitrarily set within a range from 0 to 1. The output ratio is the dutyratio of the low frequency. Also, the duty ratio of the high frequencyis defined as a value obtained by subtracting the duty ratio of the lowfrequency from 1. Therefore, the output ratio may be set to 0% such thatthe first power source 21 outputs only the high frequency, or may be setto 100% such that the first power source 21 outputs only the lowfrequency.

The second power source 26 outputs electric power of a frequencydifferent from the output frequencies of the first power source 21. Forexample, the second power source 26 outputs electric power of a lowfrequency such as 3 kHz or 8.5 kHz. Therefore, only the second powersource 26 may supply electric power to each induction heating apparatus10, or the first power source 21 may output the high frequency and thesecond power source may output only the low frequency such that electricpower is supplied to the heating coil of each induction heatingapparatus 10 by the synthetic wave of the high frequency and the lowfrequency.

In the embodiment of the present invention, since the first power source21 and the second power source 26 supply electric power at differentfrequencies to each induction heating apparatus 10, it is possible toheat workpieces to different depths from the outer surfaces of theworkpieces and to different temperatures. A more detailed descriptionwill be made below.

Switching Section

The switching section 30 include a plurality of switches to switchconnection of the power source system 20 of the first power source 21and the second power source 26 with the individual induction heatingapparatuses 10. The switching section 30 includes the first power sourceoutput switch 31 connected to the low frequency output terminal of thefirst power source 21, the second power source output switch 32connected to the output terminal of the second power source 26, thehigh-frequency input switches 33 and the low-frequency input switches 34of the individual induction heating apparatuses 10, and a switchingcontroller 35 generally controls switching of the individual switches 31to 34.

In each induction heating apparatus 10, the high-frequency input switch33 is connected to the primary winding of the high-frequency currenttransformer 11, and the low-frequency input switch 34 is connected tothe primary winding of the low-frequency current transformer 12. Theswitching controller 35 controls the output switch 31 for the firstpower source, the output switch 32 for the second power source, and thehigh-frequency input switches 33 and the low-frequency input switches 34of the individual induction heating apparatuses 10.

Power Supply Method from Power Source System to Each Induction HeatingApparatus by Switching section

As has been known, due to skin effect, at a low frequency, an eddycurrent flows up to an area deep from the outer surface of a workpiece,and at a high frequency, an eddy current flows only near the outersurface of a workpiece, that is, in a shallow area. On the basis of thiseffect, in various induction heating treatments such as quenching andtempering, it is possible to control the depths of hardened layers byfrequency differences. In this specification, this effect will bereferred to as frequency effect. When an induction heating treatment isactually performed, in order to obtain a hardened layer of anappropriate thickness, a power source for outputting an appropriatefrequency is selected.

The induction heating system shown in FIG. 1 includes the power sourcesystem 20 which is the combination of two kinds of power sources, thatis, the first power source 21 and the second power source 26. Therefore,it is possible to use only the first power source 21 to supply electricpower by the time-division method, and it is also possible to supplyelectric power to each heating coil 13 by the so-called superimposingmethod of superimposing the high frequency output from the first powersource 21 and the low frequency output from the second power source 26.In a case of using the time-division method, the output ratio of thehigh frequency fH and the low frequency fL output from the first powersource 21 is controlled. Therefore, the effect of induction heating by afrequency f between the high frequency fH and the low frequency fL(fL<f<fH) (hereinafter, this effect will be referred to as frequencyeffect) is obtained. In a case of using the superimposing method, thepower ratio of frequencies, that is, the high frequency output from thefirst power source 21 and the low frequency output from the second powersource 26 are controlled. Therefore, induction heating effect by afrequency between the high frequency and the low frequency is obtained.In other words, not only in the time-division method but also in thesuperimposing method, the single power source system 20 has amulti-frequency power source function.

In the switching section 30, a high-frequency input switch 33 and alow-frequency input switch 34 connected to an optional one of theinduction heating apparatuses 10 can be turned on so as to supplyelectric power from the power source system 20 to the induction heatingapparatus 10. Therefore, it is possible to use the single power sourcesystem 20 to supply electric power according to a heating condition toeach induction heating apparatus 10.

Since the embodiment of the present invention is fully equipped with thepower source system 20 for outputting a plurality of frequencies asdescribed above, it is possible to simultaneously or alternately outputthe high frequency and a low frequency from the power source system 20to each induction heating apparatus 10. Therefore, it is possible toarbitrarily select the ratio of the low frequency component and the highfrequency component of electric power to be supplied from the powersource system 20 to each induction heating apparatus 10, and to obtainthe frequency effect by induction heating.

Further, as shown in FIG. 1, one or more the induction heatingapparatuses 10 are connected to the single power source system 20 inaccordance with connection switching by the switching controller 35, andfor example, frequency selection, output ratio adjustment, and settingof various parameters such as intensities of the high frequency and thelow frequency are performed through the switching controller 35.Therefore, in each induction heating apparatus 10, it is possible toperform induction heating such that appropriate frequency effect isobtained. Since the single power source system 20 is used, the rate ofutilization of the power source system 20 increases, and space-savingeffect and energy-saving effect according to efficient induction heatingby an optimal frequency are obtained.

Here, each induction heating apparatus 10 has a heater controller 14,and the heater controller 14 is connected to the switching controller35. The switching controller 35 is connected to a power sourcecontroller 21 x of the first power source 21, a power source controller26 x of the second power source 26, the output switch 31 for the firstpower source, the output switch 32 for the second power source, and thehigh-frequency input switches 33 and the low-frequency input switches 34connected to the individual induction heating apparatuses 10. Therefore,all signals from the first power source 21, the second power source 26,and the heater controllers 14 of the individual induction heatingapparatuses 10 are input to the switching controller 35. All commandsignals to the first power source 21, the second power source 26, theheater controllers 14 of the individual induction heating apparatuses10, and the high-frequency input switches 33 and the low-frequency inputswitches 34 connected to the individual induction heating apparatuses 10are output by the switching controller 35. For these reasons, theswitching controller 35 may be called a system control unit.

Electric Circuit Configuration in Induction Heating System

Now, the circuit configuration between the power source system 20 and aheating coils 13 will be described in more detail, taking as an examplea case where in the induction heating system 1 shown in FIG. 1, theswitching controller 35 switches on the output switch 31 for the firstpower source, switches off the output switch 32 for the second powersource, switches on the high-frequency input switch 33 and thelow-frequency input switch 34 connected to the first induction heatingapparatus 10A, and switches off the high-frequency input switches 33 andthe low-frequency input switches 34 connected to the other inductionheating apparatuses 10B and 10C. This circuit configuration is similarlyapplied even in a case of switching on a high-frequency input switch 33and a low-frequency input switch 34 connected to a specific inductionheating apparatus 10B or 10C other than the first induction heatingapparatus 10A. However, since the distances of power supply pathsbetween the power source system 20 and the individual induction heatingapparatuses 10 depend on the induction heating apparatuses 10, theinductances of the power supply paths are different. With respect tothis matter, in order for simplifying explanation, differences among thecircuit constants of the power supply paths will not be mentioned.

FIG. 3 is a circuit diagram illustrating the circuit configurationbetween the power source system 20 and a heating coil 13 in theinduction heating system shown in FIG. 1. FIG. 3 shows a case where theoutput switch 31 for the first power source, and a high-frequency inputswitch 33 and a low-frequency input switch 34 connected to one of theinduction heating apparatuses are in ON states. The first power source21 serving as the power source system 20 has a high frequency outputterminal and a low frequency output terminal. To the high frequencyoutput terminal, the primary side of the high-frequency currenttransformer 11 is connected. To the low frequency output terminal, thelow-frequency current transformer 12 is connected. The heating coil 13is connected in parallel to each of the secondary sides of thehigh-frequency current transformer 11 and the low-frequency currenttransformer 12.

The first power source 21 includes a converter 21 a configured toconvert commercial power supplied from a commercial power source 2 intoa direct current, and an inverter 21 b configured to convert the directcurrent output from the converter 21 a into a given frequency. Both ofthe converter 21 a and the inverter 21 b are controlled by an invertercontrol unit 21 c serving as the power source controller 21 x, andparticularly, the inverter 21 b converts the direct current into adesignated frequency according to a control signal from the invertercontrol unit 21 c. With respect to the inverter 21 b, a highpass filter21 d and a lowpass filter 21 e are connected in parallel. The highfrequency output terminal is provided on the output side of the highpassfilter 21 d, and the low frequency output terminal is provided on theoutput side of the lowpass filter 21 e.

In the high-frequency current transformer 11, a transformer isconfigured by a primary winding 11 a and a secondary winding 11 b. Inthe case shown in FIG. 3, the secondary winding 11 b is connected inseries to two coils 11 d and 11 e. Between the coil 11 d and the coil 11e, a capacitor 11 c is interposed. The capacity of the capacitor 11 c isset such that the capacitor 11 c has low impedance with respect to thehigh frequency and has high impedance with respect to the low frequency.Then, it is possible to apply electric power with a good balance of thehigh frequency and the low frequency to the heating coil 13.

In the low-frequency current transformer 12, a transformer is configuredby a primary winding 12 a and a secondary winding 12 b. In the caseshown in FIG. 3, a plurality of taps 12 c is attached to the primarywinding 12 a such that it is possible to adjust the number of turns. Acore 12 d such as an iron core is provided to facilitate mutualinduction of the primary winding 12 a and the secondary winding 12 b.Further, to both ends of the secondary winding 12 b, bus bars areconnected, respectively, and each of the bus bars is connected to theheating coil 13. In FIG. 3, the bus bars are shown as their impedances12 e and 12 f. The impedances 12 e and 12 f form a kind of filter, suchthat the high frequency is not input from the high-frequency currenttransformer 11 to the low-frequency current transformer 12.

As described above, each of the high-frequency current transformer 11and the low-frequency current transformer 12 includes not only thetransformer composed of the primary winding and the secondary windingbut also a matching circuit for taking impedance matching between theheating coil 13 and the power source system 20. Also, since thehigh-frequency current transformer 11 and the low-frequency currenttransformer 12 are connected in parallel to the heating coil 13, theyincludes filter circuits, respectively, such that even if the lowfrequency flows into the secondary side of the high-frequency currenttransformer 11, the low frequency cannot be input to the secondarywinding 11 b, and even if the high frequency flows into the secondaryside of the low-frequency current transformer 12, the high frequencycannot be input to the secondary winding 12 b. Therefore, each currenttransformer may also be called a regulator circuit including atransformer, a matching circuit, and a filter circuit.

FIG. 4 is a circuit diagram illustrating another circuit configurationbetween the power source system 20 and a heating coil 13 in theinduction heating system shown in FIG. 1. FIG. 4 shows a case where theoutput switch 32 for the second power source, and a high-frequency inputswitch 33 and a low-frequency input switch 34 connected to on of theinduction heating apparatuses are in ON states.

The circuit shown in FIG. 4 is different from the circuit shown in FIG.3 in that the second power source 26 is connected to the low-frequencycurrent transformer 12 through the output switch 32 for the second powersource. For example, as shown in FIG. 4, the second power source 26 hasthe same circuit configuration as that of the first power source 21.

However, the second power source 26 is different from the first powersource 21 in that, of control of an inverter control unit 26 c, servingas the power source controller 26 x, on a converter 26 a and an inverter26 b, control on the inverter 26 b always makes electric power of aspecific frequency be output.

Arrangement of High-Frequency Current Transformer and Low-FrequencyCurrent Transformer

In the system configuration shown in FIG. 1, each induction heatingapparatus 10 includes a high-frequency current transformer 11 and alow-frequency current transformer 12. As described above, thehigh-frequency current transformer 11 has no core, whereas thelow-frequency current transformer 12 has a core. The reason why thehigh-frequency current transformer 11 has no core is that, at a highfrequency, a voltage which is applied to the primary side of atransformer is higher than that at a low frequency, and thus it isdifficult to easily make a transformer with a core capable ofwithstanding that high voltage.

In general, a core is composed of an iron core or the like. Therefore,the low-frequency current transformer 12 is heavier than thehigh-frequency current transformer 11. For this reason, in a case ofarranging the high-frequency current transformer 11 and thelow-frequency current transformer 12 one above the other, thelow-frequency current transformer 12 with the core is disposed on thelower side, and on the low-frequency current transformer 12, thehigh-frequency current transformer 11 is disposed (see FIG. 6).Therefore, it is possible to reduce the dimensions of the inductionheating apparatus 10 in a plan view, as compared to a case where thehigh-frequency current transformer 11 and the low-frequency currenttransformer 12 are arranged horizontally, side by side. Particularly, ina case of using the single power source system 20 to supply electricpower to the plurality of induction heating apparatuses 10 as shown inFIG. 1, it is preferable to make the distances between the power sourcesystem 20 and the induction heating apparatuses 10 as short as possible.In this case, connection wirings such as bus bars between the powersource system 20 and the induction heating apparatuses 10 are short, andthus the influence of the connection wirings on an inductance componentmay not need to be considered. Further, between the power source system20 and the induction heating apparatuses 10, voltage drop is suppressed.

Replacement of Low-Frequency Current Transformer—1

In the induction heating system 1 according to the embodiment of thepresent invention, the heating coils 13 according to the shapes anddimensions of heat treatment areas of workpieces are designed and aredisposed in the induction heating apparatuses 10, and according to theheating conditions of workpieces, whether to combine the frequencies,the magnitude of each frequency, and so on are selected. Further, inorder to perform induction heating on workpieces of different kinds, theheating coils 13 designed according to the heating conditions for eachworkpiece are attached in the individual induction heating apparatuses10, and according to the heating conditions set for the individualinduction heating apparatuses 10 by the single power source system 20,electric power is supplied from the power source system 20 to theinduction heating apparatuses 10. Therefore, the heating coils 13 aredifferent for each induction heating apparatus 10.

In a case where the high-frequency current transformer 11 has theprimary winding 11 a and the secondary winding 11 b but does not have acore such as an iron core as described above, it is difficult for achange in the impedance of the heating coil 13 connected to the outputterminal side of the high-frequency current transformer 11 to betransmitted to the power source system 20. Therefore, in a case wherethe heating coil 13 has high impedance, a change in the impedance of theload side seen from the power source system 20 does not increase.

However, the low-frequency current transformer 12 includes the primarywinding 12 a and the secondary winding 12 b, and includes the core 12 dsuch as an iron core to improve coupling between the primary winding 12a and the secondary winding 12 b. For this reason, if the heating coil13 connected to the output terminal side of the low-frequency currenttransformer 12 is replaced, it is easy for a change in the impedance ofthe heating coil 13 to be transmitted to the power source system 20.Therefore, in a case where the heating coil 13 has high impedance, theimpedance of the load side seen from the power source system 20 becomeshigh, and it becomes difficult to take impedance matching.

For this reason, in a case of replacing the heating coil 13, it may benecessary to replace the low-frequency current transformer 12 with onedifferent in the turn ratio of the primary winding 12 a and thesecondary winding 12 b. Regarding this point, it can be considered toprovide a number of taps to the primary winding 12 a in thelow-frequency current transformer 12 as shown in FIG. 3, therebywidening the adjustable range of the turn ratio. However, in the casewhere a number of taps are provided to the primary winding 12 a, forexample, in a transformer having taps from 4 T up to 8 T according tothe number of turns, if induction heating is performed on a workpiececapable of taking matching at the tap of 4 T, a voltage which is twice avoltage on the tap of 4 T is generated at the tap of 8 T. Since avoltage on the primary winding 12 a becomes an extremely high voltage,for example, the maximum 4000 V, according to a matching condition, ifthis voltage is applied to the tap of 4 T, at the tap of 8 T, a voltageof 8000 V is generated. Further, since the output of the first powersource 21 is extremely large as the maximum 600 kW, a possibility thatinsulation breakdown such as a spark will occur increases. Therefore, itis not practical to provide many taps for switching to the primarywinding of the low-frequency current transformer 12.

Replacement of Low-Frequency Current Transformer—2

In a case of alternately supplying the high frequency and the lowfrequency from the power source system 20 to the heating coil 13 by thetime-division method, taking impedance matching is more difficult at thelow frequency than at the high frequency. FIG. 5 is a view schematicallyillustrating signal waveforms which are output and controlled from thefirst power source 21 shown in FIG. 3. The horizontal axis representstime, and the vertical axis represents signal intensities. In FIG. 5,(a) shows the waveform of ON/OFF of the output from the first powersource 21, (b) shows the waveform of the duty ratio of the lowfrequency, (c) shows the waveform of a DC voltage Vdc of the first powersource 21, and (d) shows a DC current Idc of the first power source 21.

In a case of switching on the output of the first power source 21 toalternately output the low frequency and the high frequency, if a lowfrequency output status transitions to a high frequency output status,the DC current Idc starts to increase. In contrast, if the highfrequency output status transitions to the low frequency output status,the DC current Idc starts to decrease. With respect to the impedance ofthe load seen from the power source system 20, for example, in a casewhere the impedance of the high frequency is lower than the impedance ofthe low frequency as shown in FIG. 5, that is, in a case where theimpedance difference between the high frequency and the low frequency islarge, the DC current Idc increases or decreases as shown in FIG. 5whenever switching is performed between the high frequency and the lowfrequency. Therefore, it is preferable to adjust the impedances of thehigh frequency and the low frequency seen from the power source side tothe same degree. For this adjustment, the low-frequency currenttransformer is replaced.

Arrangement and Configuration of Each Part of Induction HeatingApparatus

Therefore, in the embodiment of the present invention, it is possible toprovide a mechanism for replacing the low-frequency current transformer(hereinafter, referred to as a replacing mechanism), for example, byretrofitting. As a premise to explain the replacing mechanism, thearrangement, configuration, and the like of the high-frequency currenttransformer 11, the low-frequency current transformer 12, the heatingcoil 13, and a power supply path (hereinafter, referred to as a “powertransmission bus bar”, or simply as a “bus bar”) for electricallyconnecting them in the induction heating apparatus 10 will be described.

Overall Configuration of Induction Heating Apparatus

FIG. 6 is a side view schematically illustrating the arrangement andconfiguration of the induction heating apparatus. In the inductionheating apparatus 10, as shown in FIG. 6, the low-frequency currenttransformer 12 and the high-frequency current transformer 11 are mountedand supported on a mounting frame 80. The low-frequency currenttransformer 12 and the high-frequency current transformer 11 areconnected to switches (not shown in FIG. 6) through primary-side busbars 81 and 83, respectively, and are connected in parallel to theheating coil 13 through a secondary-side bus bar 82. Hereinafter, on theassumption of a quenching machine for heating and cooling a workpiece, adescription will be made.

FIG. 6 shows a replacing mechanism 90 constructed as a supplement byassembling various members such that in a case where any mechanism forreplacing the low-frequency current transformer 12 is not originallyprovided on the mounting frame 80, it is possible to replace thelow-frequency current transformer 12 disposed on the mounting frame 80.In order to make it possible to withdraw the low-frequency currenttransformer 12 to the rear (to the observer's left side in FIG. 6), asanother replacing mechanism, rollers may be provided at the lower endportions of both side surfaces of the low-frequency current transformer12, and a guide member such as a rail for guiding the low-frequencycurrent transformer 12 to the rear may be attached to the mounting frame80. In this case, a replacing mechanism simpler than the replacingmechanism 90 to be described below with reference to FIGS. 6 to 10C canbe assembled.

Heating Coil

The heating coil 13 is connected to the plate-like secondary-side busbar 82 connected to the high-frequency current transformer 11 and thelow-frequency current transformer 12 such that the heating coil 13 issupported by the secondary-side bus bar. In the induction heatingapparatus 10, as the heating coil 13, one having a shape and dimensionscorresponding to the heat treatment area of a workpiece is selected andmounted. In the induction heating apparatus 10, a quenching-liquidinjection nozzle 84 for injecting quenching liquid after inductionheating is provided.

Current Transformer

The high-frequency current transformer 11 includes the primary windingand the secondary winding as described above. In the primary winding andsecondary winding of the high-frequency current transformer 11, liquidpaths are provided, respectively, to allow cooling liquid from a coolingliquid system (not shown) to pass.

The low-frequency current transformer 12 includes the primary winding,the secondary winding, and the core as described above. The core linksthe primary winding and the secondary winding. In the presentembodiment, a plurality of low-frequency current transformers 12different in the number of turns of the primary winding and thesecondary winding is prepared, and from them, one corresponding to theheating coil 13 and satisfying an impedance matching condition isselected and is disposed on the mounting frame 80. Even in the primarywinding and secondary winding of the low-frequency current transformer12, liquid paths are provided, respectively, to allow the cooling liquidfrom the cooling liquid system (not shown) to pass.

On the rear end surface of the low-frequency current transformer 12, aconnector 86 is provided, and the primary-side bus bar 83 is connectedto the connector 86 such that the primary-side bus bar is removable. Onthe front end portion of the low-frequency current transformer 12, aconnector 87 is provided, and the secondary-side bus bar 82 is connectedto the connector 87 such that the second bus bar is removable. Theliquid paths of the primary winding and secondary winding of thelow-frequency current transformer 12 are connected to the cooling liquidsystem through couplers, respectively, and are separable by thecouplers. If the connection is released such that the liquid paths areseparated from the couplers, the internal valves of the couplers closeflow paths.

Mounting Frame

The mounting frame 80 is formed of a steel angle material in a hollowand solid shape. The mounting frame 80 includes an upper supportingsection 88 for supporting the high-frequency current transformer 11 atthe upper portion, and a lower supporting section 89 provided below theupper supporting section 88 for supporting the low-frequency currenttransformer 12. In front of the upper supporting section 88 and thelower supporting section 89, the heating coil 13 is disposed. The frontsurfaces of the upper supporting section 88 and the lower supportingsection 89 are covered by cover members 91 for partitioning the uppersupporting section and the lower supporting section off from a heatingposition. As long as the mounting frame 80 has this configuration, theshape of the mounting frame is not limited to the shape shown in FIG. 6.

Replacing Mechanism

As described above, in a case where there is a simple replacingmechanism attached on the mounting frame 80, this replacing mechanismcan be used. In a case where there is no replacing mechanism on themounting frame 80, the following replacing mechanism is prepared.

As shown in FIG. 7, in the lower supporting section 89, a replacingmechanism 90 for replacing the low-frequency current transformer 12 isconstructed by assembling. This retrofitted replacing mechanism 90includes a front-rear direction support 92 which is fixed to themounting frame 80 and extends in a front-rear direction, a base plate 93which is supported on the front-rear direction support 92 such that thebase plate is displaceable in the front-rear direction, and a carriage94 which is movable in the front-rear direction on the traveling surfaceof the top of the base plate 93. If the mounting frame 80 originally hasno replacing mechanism, when the low-frequency current transformer 12disposed on the mounting frame 80 as shown in FIG. 10A is replaced withanother low-frequency current transformer, a worker inserts the baseplate 93 between the low-frequency current transformer 12 and thefront-rear direction support 92, so as to displace the base plate 93 tothe front side. Then, the base plate 93 runs on an inclined member 96attached to the front side of the mounting frame 80 in front such thatthe base plate 93 slightly rises (FIG. 10B). As will be described below,the worker raises the rear end of a carriage plate 94 b by a verticaldisplacement means 97 so as to level the carriage plate 94 b, therebysupporting the low-frequency current transformer 12 by the carriageplate 94 b, with a gap from the mounting frame 80 (FIG. 10C), and thenslides the low-frequency current transformer 12 together with thecarriage 94 to the rear side.

The front-rear direction support 92 may be a portion of the mountingframe 80, or may be a member like a plate fixed to the mounting frame80. The front-rear direction support 92 is configured to stably supportthe base plate 93 with sufficient strength to support the low-frequencycurrent transformer 12. The base plate 93 has strength capable ofsupporting the low-frequency current transformer 12, and has a travelingsurface 93 a for the carriage 94 on the top as shown in FIGS. 8A to 9.At the left and right edges of the top surface of the base plate 93,base ribs 93 c are provided to extend substantially in parallel to eachother in the front-rear direction. The provision of the base ribs 93 cmakes it possible to secure the strength of the base plate 93 and thinthe base plate 93.

As shown in FIGS. 8A to 9, a pair of side edge guide units 80 a is fixedto the mounting frame 80 to extend in the front-rear direction along theleft and right edges of the base plate 93. If the mounting frameoriginally has no replacing mechanism, the low-frequency currenttransformer 12 is supported by the pair of side edge guide units 80 a.The base plate 93 is disposed between the pair of side edge guide units80 a and is mounted on the front-rear direction support 92. The outersurfaces of the left and right base ribs 93 c are slidable toward theinner surfaces of the side edge guide units 80 a, respectively.Therefore, the base ribs 93 c can be guided by the side edge guide units80 a such that the base plate 93 is displaced in the front-reardirection. Although not particularly limited, the base plate 93 arepreferably disposed horizontally.

On the left and right sides of the rear end side of the base plate 93,front displacement means 95 are provided to connect the base plate 93and the mounting frame 80 and make the base plate 93 displaceable backand forth with respect to the mounting frame 80. The front displacementmeans 95 include fixed blocks 95 a that are fixed to the mounting frameat the left and right of the rear end side of the base plate 93, baseprotrusion portions 93 b that are disposed to protrude left and rightfrom the rear end of the base plate 93 and face the rear sides of thefixed blocks 95 a, and pushing screw portions 95 b that are fixed to thefixed blocks 95 a through the base protrusion portions 93 b. In thefront displacement means 95, it is possible to rotate screwing members95 c of the pushing screw portions 95 b to press the base protrusionportions 93 b, thereby advancing the base plate 93.

At a position of the mounting frame 80 corresponding to the front endside of the base plate 93, as shown in FIG. 10, the inclined member 96is provided and fixed on the front-rear direction support 92. Theinclined member 96 has a gradient such that its front side is higher. Asthe inclined member 96, a wedge-shaped plate extending over the fullwidth of the lower supporting section 89 in the left-right direction isused. If the base plate 93 is advanced by the front displacement means95, the front end side of the base plate 93 can run on the inclinedmember 96, and it is possible to raise the front end side of the baseplate 93 with respect to the front-rear direction support 92 accordingto the amount of advance.

As shown in FIGS. 7 to 8B, the vertical displacement means 97 isprovided on the rear end side of the base plate 93, and is used tovertically displace the rear end side of the base plate 93 with respectto the mounting frame 80. For example, the vertical displacement means97 is composed of a plurality of screw members screwed to the rear endside of the base plate 93. Each screw member can be screwed in the baseplate to raise the base plate 93 from the front-rear direction support92 of the mounting frame 80.

As shown in FIGS. 7 to 9, the carriage 94 includes the plate-likecarriage plate 94 b, a plurality of left rollers 98 and a plurality ofright rollers 98 that are arranged in lines in the front-rear directionon the left and right edge sides of the lower surface of the carriageplate 94 b, respectively, and can roll, and a handle 94 a that is fixedon the rear end side of the carriage plate 94 b such that the handleprotrudes from the top surface of the carriage plate.

On the lower surface of the carriage plate 94 b, a pair of carriage ribs94 c is provided to extend in the front-rear direction along the linesof the left and right rollers 98. Therefore, it is possible to securethe strength of the carriage plate 94 b and to thin the carriage plate94 b. On each side of the carriage 94, at least three or more rollers98, preferably, further more rollers 98 are arranged in parallel to oneanother. Since many rollers 98 are disposed, it is possible todispersively load the weight of the low-frequency current transformer 12on the individual rollers 98. To the carriage 94, each member is fixedby bolts or screws, not by welding. Therefore, it is possible to preventdeformations of the carriage 94 and to stably operate the carriage 94 ina small space.

The carriage plate 94 b is formed in a flat plate shape, and on thefront end sides and rear end sides of the left and right of the carriageplate 94 b, cam followers 94 d are disposed to abut on the inner surfaceof the left and right base ribs 93 c and roll thereon. While theplurality of rollers 98 rolls on the traveling surface 93 a of the baseplate 93, the cam followers 94 d abut on the inner surfaces of the baseribs 93 c and roll thereon. Therefore, the carriage 94 is movable backand forth along the base ribs 93 c on the base plate 93.

It is preferable that it is possible to attach a jig 99 for locking thefront end edge of the low-frequency current transformer 12 and a jig 99for locking the rear end edge of the low-frequency current transformer12 to the top surface of the carriage plate 94 b, as shown in FIGS. 8Aand 8B. The jigs 99 locate the low-frequency current transformer 12 at apredetermined position on the carriage plate 94 b. The jigs 99 areformed in rod shapes, and are fixed to extend in the width direction ofthe carriage 94. On the side surfaces of the jigs 99, guide surfaces 99a are provided to guide the front end edge or rear end edge of thelow-frequency current transformer 12 when the low-frequency currenttransformer 12 is placed on the carriage plate 94 b.

At each of a plurality of positions of the carriage plate 94 b, aplurality of fixing positions for the jigs 99 is provided. Therefore, itis possible to select fixing positions and fix the jigs 99, therebycapable of using the jigs for a plurality of low-frequency currenttransformers 12 different in length in the front-rear direction. Thejigs 99 are fixed to the top surface of the carriage 94 by jig fixingscrews 99 b, respectively. The jig fixing screw 99 b of each jig 99 canbe eccentrically disposed on one side with respect to the center of thewidth direction of the corresponding jig 99, be reversed in thefront-rear direction, and be fixed, whereby it is possible to change theguide surface 99 a of each jig 99 between two positions. Therefore, itis possible to use the same jigs 99 to locate low-frequency currenttransformers 12 different in length in the front-rear direction, on thecarriage 94.

The carriage 94 with the low-frequency current transformer 12 locatedthereon can advance, thereby disposing the low-frequency currenttransformer 12 at the connection position P1 with the heating coil 13,and can retreat, thereby disposing the low-frequency current transformer12 at a replacement position P2.

As shown in FIGS. 10A and 10B, at a position of the mounting frame 80facing the front edge of the carriage 94, a carriage stopper 80 b isprovided to abut on the carriage 94. The amount of protrusion of thecarriage stopper 80 b can be adjusted to adjust the contact positionwith the carriage 94 and accurately dispose the low-frequency currenttransformer 12 at the connection position.

The cover member 91 provided on the front side of the lower supportingsection 89 has a size to cover the front side of the lower supportingsection 89, and is disposed such that the front end surface of thelow-frequency current transformer 12 disposed at the connection positionP1 can abut on and be attached firmly to the cover member. At the centerof the cover member 91, a connection opening 91 a is formed to allow theconnector 87 of the low-frequency current transformer 12 to be disposedtherein. Around the connection opening 91 a, an endless packing 91 b isdisposed to surround the connection opening 91 a. If the low-frequencycurrent transformer 12 is disposed at the connection position P1, theperiphery of the connector 87 of the low-frequency current transformer12 is attached firmly to the packing 91 b. Due to the packing 91 b, whenthe quenching liquid is injected at the heating position, it is possibleto surely prevent the quenching liquid from penetrating into the covermember. The crushing margin of the packing 91 b can be adjusted byadjusting the contact position of the carriage stopper 80 b.

Now, a case of replacing a low-frequency current transformer 12A,mounted on a mounting frame 80 having no replacing mechanism as shown inFIG. 6, with another low-frequency current transformer 12B will bedescribed.

In the mounting frame 80 having no replacing mechanism, as shown in FIG.6, the primary-side bus bar 83 is connected to the connector 86 of therear side of the low-frequency current transformer 12A, and thesecondary-side bus bar 82 is connected to the connector 87 of the frontside of the low-frequency current transformer 12A, and the heating coil13 is connected to the secondary-side bus bar 82. The secondary windingof the high-frequency current transformer 11 and the secondary windingof the low-frequency current transformer 12A are connected in parallelwith respect to the heating coil 13. The primary-side bus bar 83, thesecondary-side bus bar 82, and the liquid paths of the primary windingand secondary winding of the low-frequency current transformer 12A areconnected to the cooling liquid system by the couplers. Under thissituation, the low-frequency current transformer 12A and theprimary-side bus bar 83 are disconnected, and the low-frequency currenttransformer 12A and the secondary-side bus bar 82 are disconnected, andthe couplers of the cooling liquid paths are removed.

In this way, the low-frequency current transformer 12A is ready to bereplaced. First, as shown in FIG. 10A, on the front left and right endsides of the front-rear direction support 92, near to the cover member91, the inclined member 96 is disposed to get higher from the rear tothe front. In this case, as shown in FIG. 10A, the low-frequency currenttransformer 12B is supported by the angles of the mounting frame 80,specifically, the angles of carrying supports 80 c of the upper ends ofthe side edge guide units 80 a.

Next, the base plate 93 is inserted between the low-frequency currenttransformer 12A and the front-rear direction support 92, and thecarriage 94 is driven on the base plate 93 such that the carriage 94 isinserted between the low-frequency current transformer 12A and the baseplate 93 until the carriage stopper 80 b abuts on the mounting frame 80.In this state, between the low-frequency current transformer 12A and thecarriage 94, a gap still exists.

Next, the front displacement means 95 are disposed on the left and rightsides of the rear end side of the base plate 93, and are connected tothe base plate 93 and the mounting frame 80. The screwing members 95 cof the front displacement means 95 are rotated to displace the baseplate 93 fourth, such that the forward small force causes an upwardlarge force by wedge effect according to the inclination of the inclinedmember 96. In this way, the base plate 93 is displaced forward to run onthe inclined member 96 attached to the front side of the mounting frame80 in front, such that the base plate 93 slightly rises.

Next, the vertical displacement means 97 raises the rear end of thecarriage plate 94 b so as to level the carriage plate 94 b, therebysupporting the low-frequency current transformer 12 by the carriageplate 94 b with a gap from the mounting frame 80 (FIG. 10C), and thenthe low-frequency current transformer 12 is slid together with thecarriage 94 to the rear side. In this case, since an extension plate 93d is disposed to be smoothly connected to the top surface of the baseplate 93 on the rear side of the base plate 93, the low-frequencycurrent transformer 12A is moved together with the carriage 94 to thereplacement position P2 where the low-frequency current transformer 12Adoes not vertically overlap the high-frequency current transformer 11,and is taken out. Next, in a state where the carriage 94 is still at thereplacement position P2, the low-frequency current transformer 12A isunloaded from the carriage 94, for example, by a crane (not shown).

Next, another low-frequency current transformer 12B is mounted on thecarriage plate 94 b, for example, by the crane (not shown), and thecarriage 94 is advanced on the base plate 93. The front end of thecarriage plate 94 b is made to about on the carriage stopper 80 b, suchthat the carriage 94 stops. In this way, it is possible to performpositioning in the front-rear direction such that the low-frequencycurrent transformer 12 is disposed at the connection position P1.

Next, in order to fix the carriage 94, the carriage 94 is fixed to thebase plate 93 by a fixing member 94 e as shown in FIGS. 8A and 8B.

Here, the connector 86 of the rear side of the low-frequency currenttransformer 12B and the connector 87 of the front side of thelow-frequency current transformer 12B are disposed at positions slightlyhigher than those of the primary-side bus bar 83 and the secondary-sidebus bar 82 before the replacement of the low-frequency currenttransformer 12A. Therefore, mounting holes for the primary-side bus bar83 and the secondary-side bus bar 82 may be expanded for positionadjustment, and the primary-side bus bar and the secondary-side bus barare connected to the mounting holes.

As described above, with the base plate 93, the inclined member 96, andthe front displacement means 95 assembled together, it is possible toretrofit the replacing mechanism 90 to the mounting frame 80 by the baseplate 93, the inclined member 96, the front displacement means 95, andthe carriage 94.

After the retrofitting, in a case of replacing the low-frequency currenttransformer 12, the fixing member 94 e is removed from the base plate93, the carriage 94 on the base plate 93 is retreated, and thelow-frequency current transformer is taken out.

Therefore, in a case of using a induction heating apparatus 10 toperform a quenching process on a workpiece, a heating coil 13corresponding to the workpiece and an area to be quenched is selected,and a low-frequency current transformer 12 satisfying an impedancematching condition corresponding to the selected heating coil 13 isselected. Even if a high-frequency current transformer 11 is disposed onthe upper supporting section 88 of the mounting frame 80 in advance, itis possible to dispose the selected low-frequency current transformer 12at the lower supporting section 89.

Since the low-frequency current transformer 12 and the high-frequencycurrent transformer 11 are disposed to vertically overlap each other asshown in FIG. 6, it is possible to reduce the disposition space.Further, since the low-frequency current transformer 12 has a core andhas a weight larger than that of the high-frequency current transformer11, if the low-frequency current transformer 12 is disposed below thehigh-frequency current transformer 11, it is possible to lower thecenter of the induction heating apparatus 10 and stably dispose theentire induction heating apparatus 10.

In the induction heating apparatus 10, the low-frequency currenttransformer 12 and the high-frequency current transformer 11 areconnected in parallel to the heating coil 13, and the low-frequencycurrent transformer 12 and the high-frequency current transformer 11 areconnected to the power source system 20 through switches, respectively.Therefore, if the switches are appropriately switched, it is possible toimplement various heating effects, and implement appropriate heatingaccording to the heat treatment area of a workpiece.

Particularly, it is possible to select any one from the plurality ofheating coils 13 having different impedances, and mount it on thesecondary-side bus bar 82, and it is possible to select onelow-frequency current transformer satisfying an impedance matchingcondition corresponding to a heating coil 13 from the plurality oflow-frequency current transformers 12 different in the turn ratio of theprimary winding and the secondary winding. Replacement of thelow-frequency current transformer 12 makes it possible to satisfy animpedance matching condition corresponding to a heating coil 13 andefficiently implement various heating effects according to workpieces.

Here, the replacing mechanism 90 is not limited to each inductionheating apparatus 10 of the induction heating system 1 shown in FIG. 1,but can be used even in the following case. For example, even in aninduction heating apparatus 10 with one current transformer, in a casewhere there is another member disposed on the current transformer, andthus detachment or attachment of the current transformer from above isimpossible, if the replacing mechanism 90 as described above isprovided, it is possible to easily perform attachment and detachment ofthe current transformer. If the current transformer is broken down, itis possible to take out the current transformer from the mounting frame80 and fix the current transformer.

In the induction heating system 1 shown in FIG. 1, the single powersource system 20 supplies electric power to the plurality of inductionheating apparatuses 10. Therefore, from the power source system 20 tothe induction heating apparatuses 10, specifically, to thehigh-frequency input switches 33 and the low-frequency input switches 34attached to the induction heating apparatuses 10, the bus bars are usedfor power supply. Since a single power source system 20 is not providedfor each induction heating apparatus 10, it is impossible to reduce thedistances between the individual induction heating apparatuses 10 andthe single power source system 20. For this reason, the bus bars areprovided to ensure the distances. On the other hand, in the inductionheating system 1 according to the embodiment of the present invention,the single power source system 20 is used to supply a large amount ofelectric power with a high voltage of an order of several thousandsvolts. Those points should be considered with respect to a way todispose the bus bars. Hereinafter, they will be described sequentially.

High-Frequency Power Supply Path and Low-Frequency Power Supply Path

A high-frequency power supply path and a low-frequency power supply pathare disposed in a duct of a case accommodating matching boxes, switches,current transformers, and the like. FIGS. 11A and 11B are across-sectional view and a plan view illustrating a status where thehigh-frequency power supply path and the low-frequency power supply pathare disposed in the frame of a duct, respectively. A duct frame 51 iscomposed of vertical frames 51 a, horizontal frames 51 b, and a depthframe 51 c such that the duct frame has a rectangular shape in across-sectional view and extends in a depth direction. Inside the frame,one bus bar 52 a and another bus bar 52 b are disposed with a gap,whereby a high-frequency power supply path 52 is provided, and one busbar 53 a and another bus bar 53 b are disposed with a gap, whereby alow-frequency power supply path 53 is provided.

As described above, since electric power is supplied to the plurality ofinduction heating apparatuses 10 by the single power source system 20,the distances from the power source system 20 to the individualinduction heating apparatuses 10 lengthen. Therefore, the impedances ofthe pairs of bus bars increase. Then, in a circuit configured byconnecting the power source system 20, the current transformers 11 and12, and the heating coils 13, it becomes possible to ignore theinfluence of the impedances of the bus bars, and a resonant frequencydrops. Particularly, if electric power of a high frequency of about 200kHz is supplied, reactance increases, and voltage drops in the powersupply paths increase.

For this reason, in the embodiment of the present invention, in order tomake the impedances of the power transmission bus bars as small aspossible, the widths of the bus bars are set to be large, and the gapbetween the bus bars 52 a and 52 b and the gap between the bus bars 53 aand 53 b are set to be as small as possible.

As shown in FIGS. 11A and 11B, between the pair of left and rightvertical frames 51 a, the pair of bus bars 52 a and 52 b forhigh-frequency power transmission and the pair of bus bars 53 a and 53 bfor low-frequency power transmission are arranged side by side. In thiscase, in a plan view, the gap L_(H) between the bus bars 52 a and 52 bfor high-frequency power transmission is set to be larger than the gapL_(L) between the bus bars for low-frequency power transmission. Forexample, the gap L_(H) is set to 60 mm to 100 mm, and the gap L_(L) isset to 10 mm to 50 mm. The reason why the gap L_(H) is set to be largerthan the gap L_(L) is that the voltage of the high frequency is higherthan the voltage of the low frequency. At the upper and lower portionsof the power transmission bus bars, there are hooks 52 c, 52 d, 53 c,and 53 d for mounting called ears. The hooks 52 c, 52 d, 53 c, and 53 dfor mounting provided at the upper and lower portions of the powertransmission bus bars 52 a, 52 b, 53 a, and 53 b are fixed to thevertical frames 51 a with insulators interposed therebetween. Each powertransmission bus bar 52 a, 52 b, 53 a, or 53 b have the hooks 52 c, 52d, 53 c, or 53 d for mounting provided with a gap in the longitudinaldirection, that is, the disposition direction.

If the gap L_(H) between the power transmission bus bars 52 a and 52 band the gap L_(L) between the power transmission bus bars 53 a and 53 bare set to be large, the gap between the bus bar 52 b for high-frequencypower transmission and the bus bar 53 a for low-frequency powertransmission narrows. Further, since a high voltage of several thousandsvolts is applied to all of the power transmission bus bars 52 a, 52 b,53 a, and 53 b, there is a possibility that insulation breakdown willoccur. For this reason, the pair of the bus bars 52 a and 52 b forhigh-frequency power transmission and the pair of the bus bars 53 a and53 b for low-frequency power transmission are provided such that thehooks 52 d and 53 c of the bus bars 52 b and 53 a facing each otherdeviate from each other.

Further, all of the power transmission bus bars 52 a, 52 b, 53 a, and 53b are fixed to the horizontal frames 51 b with insulators 54 interposedtherebetween. The horizontal frames 51 b have elongated holes 55 formedalong the horizontal frames 51 b, respectively, and the elongated holes55 make it possible to adjust the horizontal frames 51 b, the insulators54, and the gaps among the power transmission bus bars 52 a, 52 b, 53 a,and 53 b.

Switch

In the induction heating system shown in FIG. 1, as switches, the outputswitch 31 for the first power source, the output switch 32 for thesecond power source, the high-frequency input switches 33, and thelow-frequency input switches 34 are provided. These switches have almostthe same configuration. FIGS. 12A and 12B are a plan view and a frontview illustrating the configuration of each switch in the inductionheating system shown in FIG. 1, respectively.

In a switch 60, an upstream bus bar mounting portion 61 a and adownstream bus bar mounting portion 61 b of one phase of two phases, forexample, an U phase and a V phase are provided to face each other andstand on a base plate 63, and an upstream bus bar mounting portion 62 aand a downstream bus bar mounting portion 62 b of the other phase areprovided to face each other and stand on a base plate 63. The upstreambus bar mounting portions 61 a and 62 a and the downstream bus barmounting portions 61 b and 62 b have cooling flow paths (not shown)formed therein and connected to a cooling water inlet 64 a and a coolingwater outlet 64 b provided at the lower surface of the base plate 63.

In order to prevent insulation breakdown between the upstream and downbus bar mounting portions 61 a and 61 b and between the upstream anddownstream bus bar mounting portions 62 a and 62 b, in the base plate63, between the upstream and down bus bar mounting portions 61 a and 61b and between the upstream and downstream bus bar mounting portions 62 aand 62 b, elongated holes 63 a and 63 b are formed, respectively, suchthat creepage distances are set to be long. Further, in order to preventinsulation breakdown between the downstream bus bar mounting portion 61b of the one phase and the upstream bus bar mounting portion 62 a of theother phase, in the base plate 63, between the upstream bus bar mountingportion 62 a and the downstream bus bar mounting portion 61 b, aelongated hole 63 c is formed to set a creepage distance to be long.

As described above, at each phase, the upstream bus bar mounting portion61 a or 62 a and the downstream bus bar mounting portion 61 b or 62 bare provided to stand on the base plate 63 with the gap. Each ofconnection blocks 65 abuts on the end surfaces of two of the bus barmounting portions 61 a, 61 b, 62 a, and 62 b such that both bus barmounting portions are electrically connected, whereby switching isperformed. To this end, one connection block 65 is provided for eachphase. As shown in FIGS. 12A and 12B, each connection block 65 includesa contact portion 65 a for electrically connecting the upstream bus barmounting portion 61 a or 62 a and the downstream bus bar mountingportion 61 b or 62 b, a support 65 b for supporting the contact portion65 a to be rotatable on a vertical shaft, and a rod 65 c that extendsfrom the support 65 b toward the opposite side to the contact portion 65a. On the base plate 63, at a position on the opposite side of theconnection blocks 65 to the upstream bus bar mounting portions 61 a and62 a and the downstream bus bar mounting portions 61 b and 62 b, asupport block 66 is disposed to be able to be displaced to the left andright by an air cylinder 67. The rods 65 c of the connection blocks 65of the individual phases pass through one support block 66, andcompression springs 68 are mounted on the rods 65 c and bias theconnection block 65. As shown in FIGS. 12A and 12B, each connectionblock 65 rotates on a vertical shaft within a predetermined range.Therefore, if the support block 66 is displaced to one side by the aircylinder 67, according to the displacement, the individual connectionblocks 65 are displaced to one side, and are surely pressed against theend surfaces of the upstream and downstream bus bar mounting portion 61a and 61 b and the end surfaces of the upstream and downstream bus barmounting portion 62 a and 62 b by compression springs 68.

Also, on the base plate 63, cooling pipes 69 for introducing the coolingwater to the connection blocks 65 and discharging the cooling water fromthe connection blocks 65, a solenoid valve 70 for controlling injectionand discharge of air with respect to the air cylinder 67, and a limitswitch 71 for confirming the advance end and retreat end of the aircylinder 67 are provided.

On the lower surface of the base plate 63, a plurality of insulators 72is attached such that the switch 60 is electrically insulated. Theconnection blocks 65, the upstream bus bar mounting portions 61 a and 62a, and the downstream bus bar mounting portions 61 b and 62 b arewater-cooled by the cooling water. To this end, various detectingsensors are attached to detect whether the flow of the cooling water hasexceed a defined value, or to detect an anomaly in the air cylinder orthe pipe necessary for the air cylinder. If an anomaly of air pressureor an anomaly of the flow of the cooling water is detected by adetecting sensor, the switch 60 sends an air pressure anomaly signal ora cooling water flow anomaly signal to the switching controller 35.Then, the switching controller 35 commands each induction heatingapparatus and the power source system not to perform a system operation.

Method of Sequentially Heating Multiple Workpieces by Induction HeatingSystem

While describing a method of sequentially heating workpieces by eachinduction heating apparatus 10 in the induction heating system 1 shownin FIG. 1, the induction heating system will be described in detail.

FIG. 13 is a view illustrating a sequence in which each inductionheating apparatus 10 performs induction heating on a workpiece by theinduction heating system 1 shown in FIG. 1, and particularly shows acase where the first induction heating apparatus 10A receives electricpower from the first power source 21 by the time-division method, andperforms a heat treatment.

In ST1-1, the first induction heating apparatus 10A sends an OFF-to-ONswitching request signal to the switching controller 35.

In ST1-2, upon receipt of the OFF-to-ON switching request signal, theswitching controller 35 sends an OFF-to-ON switching request signal tothe output switch 31 for the first power source.

In ST1-3, upon receipt of the OFF-to-ON switching request signal, theoutput switch 31 for the first power source performs an OFF-to-ONswitching control.

In ST1-4, when the OFF-to-ON switching control is completed, the outputswitch 31 for the first power source sends a switching completion signalto the switching controller 35.

In ST1-5, upon receipt of the OFF-to-ON switching request signal, theswitching controller 35 sends an OFF-to-ON switching request signal tothe high-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus 10A.

In ST1-6, upon receipt of the OFF-to-ON switching request signal, thehigh-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus 10A perform OFF-to-ONswitching controls.

In ST1-7, the high-frequency input switch 33 and the low-frequency inputswitch 34 connected to the first induction heating apparatus 10A sendswitching completion signals to the switching controller 35.

In ST1-8, upon receipt of the OFF-to-ON switching completion signalsfrom the output switch 31 for the first power source, and thehigh-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus 10A, the switchingcontroller 35 sends a switching completion signal to the first inductionheating apparatus 10A.

In ST1-9, upon receipt of the switching completion signal in ST1-8, thefirst induction heating apparatus 10A sends an output start signal tothe first power source 21.

Upon receipt of the output start signal in ST1-9, the first power source21 supplies electric power to the first induction heating apparatus onthe basis of output control information received together with theoutput start signal. Here, the output control information is outputcontrol information notified to the first power source 21, and examplesof the items of the output control information include identificationinformation on whether to all of the high frequency and the lowfrequency are output or only the high frequency is output, the outputratio of the high frequency and the low frequency, each outputintensity, a frequency value in a case where frequency setting ispossible, a total output time, etc.

In ST1-10, when the first power source 21 terminates the power supplybased on the output control information, the first power source 21 sendsa power supply termination signal to the first induction heatingapparatus 10A.

In ST1-11, upon receipt of the power supply termination signal, thefirst induction heating apparatus 10A sends an ON-to-OFF switchingrequest signal to the switching controller 35.

In ST1-12, Upon receipt of the ON-to-OFF switching request signal, theswitching controller 35 sends an ON-to-OFF switching request signal tothe output switch 31 for the first power source. Also, when theswitching controller 35 receives the ON-to-OFF switching request signal,if there is a switching request signal having been input from anotherinduction heating apparatus, for example, a second induction heatingapparatus 10B, according to the request of the second induction heatingapparatus 10B, the switching controller 35 switches one or more switchesof the output switch 31 for the first power source, the output switch 32for the second power source, and the high-frequency input switch 33 andthe low-frequency input switch 34 of the second induction heatingapparatus 10B. If there is no switching request signal having beenreceived from another induction heating apparatus, the switchingcontroller 35 maintains the switches at the current states.

In ST1-13, upon receipt of the first power source receives the ON-to-OFFswitching request signal, the output switch 31 performs an ON-to-OFFswitching control.

In ST1-14, when the ON-to-OFF switching control is completed, the outputswitch 31 for the first power source sends a switch completion signal tothe switching controller 35.

In ST1-15, upon receipt of the ON-to-OFF switching request signal, theswitching controller 35 sends an ON-to-OFF switching request signal tothe high-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus 10A.

In ST1-16, upon receipt of the ON-to-OFF switching request signal, thehigh-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus 10A perform ON-to-OFFswitching controls.

In ST1-17, when the switching is completed, the high-frequency inputswitch 33 and the low-frequency input switch 34 connected to the firstinduction heating apparatus 10A send a switching completion signals tothe switching controller 35.

Here, ST1-2 and ST1-5 may be performed at the same time, or one afterthe other. ST1-12 and ST1-15 may be performed at the same time, or oneafter the other.

In the sequence shown in FIG. 13, once it receives a request forswitching to the ON state from the first induction heating apparatus10A, the switching controller 35 is maintained at a standby state evenwhen it receives a signal for requesting switching to the ON state fromanother induction heating apparatus, until receiving a switchingcompletion signal of switching from the ON state to the OFF state inST1-17. Then, upon receipt of a switching completion signal of switchingfrom the ON state to the OFF state in ST1-17, the switching controller35 performs a process according to the switching request signal fromanother induction heating apparatus.

This sequence can be used for the single power source system 20 tohandle switching requests from the plurality of induction heatingapparatuses 10, without batting.

In the sequence described with reference to FIG. 13, a case of using aplurality of induction heating apparatuses to perform induction heatinghas been assumed. However, it is possible to repeat the heat treatmentin only one induction heating apparatus using the system shown inFIG. 1. In this case, an output switch is maintained at a connectionstate with only the induction heating apparatus 10A. Therefore, it ispossible to extend the life of the output switch. Also, whenever aswitching request signal from another induction heating apparatusdisappears, the switch may be switched off. The sequence shown in FIG.13 is an example, and can be changed as follows.

If the switching controller 35 receives the switching completion signalsof the switching from the OFF state to the ON state, from the outputswitch 31 for the first power source, and the high-frequency inputswitch 33 and the low-frequency input switch 34 connected to the firstinduction heating apparatus 10A, the switching controller 35 sends theoutput start signal directly to the first power source 21, instead ofSTEPS ST1-8 and ST1-9 of FIG. 13. Upon receipt of the output startsignal from the switching controller 35, the first power source 21supplies electric power to the first induction heating apparatus 10A onthe basis of the output control information received together with theoutput start signal. The items of the output control information are thesame as described above.

If the first power source 21 terminates the power supply based on theoutput control information, instead of STEPS ST1-10 and ST1-11 of FIG.13, the first power source 21 performs switching control to switch theoutput switch 31 for the first power source from the ON state to the OFFstate in ST1-12, and the switching controller 35 sends the ON-to-OFFswitching request signal to the high-frequency input switch 33 and thelow-frequency input switch 34 connected to the first induction heatingapparatus 10A in ST1-15.

In FIG. 13, the first induction heating apparatus 10A takes theinitiative, and controls the first power source 21, the switchingcontroller 35, the output switch 31 for the first power source, and thehigh-frequency input switch 33 and the low-frequency input switch 34connected to the first induction heating apparatus. However, thesequence control of the induction heating system shown in FIG. 1 may besequence control other than that shown in FIG. 13. For example, theswitching ON request sent from the first induction heating apparatus 10Ato the switching controller 35 may serve as a trigger and together withthe switching request, the output control information may be output tothe switching controller 35, and the switching controller 35 may controlthe first power source 21, the output switch 31 for the first powersource, and the high-frequency input switch 33 and the low-frequencyinput switch 34 connected to the first induction heating apparatus. Likethis, the switching controller 35 controls not only switching of eachswitch but also the first power source 21. For this reason, theswitching controller 35 may be called the system control unit.

FIG. 14 shows a sequence in which each induction heating apparatus 10performs induction heating on a workpiece by the induction heatingsystem 1 shown in FIG. 1, and particularly shows a case where the firstinduction heating apparatus 10A receives power supply from the firstpower source 21 and the second power source 26 by the superimposingmethod, and performs a heat treatment. The sequence of FIG. 14 isdifferent from the sequence of FIG. 13 in that, instead of the outputswitch 31 for the first power source, the output switch 32 for thesecond power source is controlled, and instead of STEPS ST1-9 andST1-10, the following process is performed.

If the first induction heating apparatus 10A receives the switchingcompletion signal in ST1-8, in ST2-9 replacing ST1-9, the firstinduction heating apparatus 10A sends output start signals to the firstpower source 21 and the second power source 26, respectively.

Upon receipt of the output start signals by ST2-9, the first powersource 21 and the second power source 26 supply electric power to thefirst induction heating apparatus 10A on the basis of the output controlinformation received together with the output start signals. Here, theoutput control information may include identification informationrepresenting that only the high frequency is output, an outputintensity, a total output time, etc., as items which are notified to thefirst power source 21. Also, the output control information may includean output intensity, a frequency value in a case where frequencyselecting is possible, a total output time, etc., as items which arenotified to the second power source 26.

If the first power source 21 and the second power source 26 terminatethe power supply on the basis of the output control information, inST2-10 replacing ST1-10, the first power source 21 and the second powersource 26 send power supply termination signals to the first inductionheating apparatus 10A.

If the first induction heating apparatus 10A receives the power supplytermination signals from the first power source 21 and the second powersource 26, in ST1-11, the first induction heating apparatus 10A sendsthe ON-to-OFF switching request signal to the switching controller 35.

The sequence shown in FIG. 14 is an example, and can be variouslychanged, like the case of FIG. 13. If the switching controller 35receives the switching completion signals of the switching from the OFFstate to the ON state, from the output switch 32 for the second powersource, and the high-frequency input switch 33 and the low-frequencyinput switch 34 connected to the first induction heating apparatus 10A,instead of STEPS ST1-8 and ST2-9 of FIG. 14, the switching controller 35may send output start signals to the first power source 21 and thesecond power source 26, respectively. Upon receipt of the output startsignals, the first power source 21 and the second power source 26 maysupply electric power to the first induction heating apparatus 10A onthe basis of the output control information received together with theoutput start signals. The items of the output control information arethe same as described above.

If the first power source 21 and the second power source 26 terminatethe power supply based on the output control information, instead ofSTEPS ST2-10 and ST1-11 of FIG. 14, the first power source 21 and thesecond power source 26 may send power supply termination signals to theswitching controller 35. Then, in STEPS ST1-12 and ST1-15, the switchingcontroller 35 sends the ON-to-OFF switching request signal, to theoutput switch 32 for the second power source, and the high-frequencyinput switch 33 and the low-frequency input switch 34 connected to thefirst induction heating apparatus 10A.

In FIG. 14, the first induction heating apparatus 10A takes theinitiative, and controls the first power source 21, the second powersource 26, the switching controller 35, the output switch 31 for thefirst power source, and the high-frequency input switch 33 and thelow-frequency input switch 34 connected to the first induction heatingapparatus. However, the sequence control of the induction heating systemshown in FIG. 1 may be sequence control other than that shown in FIG.14. For example, a switching ON request sent from the first inductionheating apparatus 10A to the switching controller 35 may serve as atrigger, and together with the switching request, the output controlinformation may be output to the switching controller 35, and theswitching controller 35 may perform sequence control on the first powersource 21, the second power source 26, the output switch 31 for thefirst power source, and the high-frequency input switch 33 and thelow-frequency input switch 34 connected to the first induction heatingapparatus. Like this, the switching controller 35 controls not onlyswitching of each switch but also the first power source 21 and thesecond power source 26. For this reason, the switching controller 35 maybe called the system control unit.

This sequence shown in FIG. 14 can be used for the single power sourcesystem 20 to handle switching requests from the plurality of inductionheating apparatuses 10, without batting.

Like the sequence controls shown in FIGS. 13 and 14, the single powersource system 20, that is, a power supply apparatus can be connected toone of the plurality of induction heating apparatuses 10, and supplyelectric power thereto. The reason is that the heater controller 14 andthe switching controller 35 of each induction heating apparatus 10 shownin FIG. 1 have the following functions.

That is, the heater controller 14 requests the switching controller 35 acommand to switch on one of the output switch 31 for the first powersource and the output switch 32 for the second power source and toswitch off the other, and a command to switch on or off each of thehigh-frequency input switch 33 and the low-frequency input switch 34.

If the switching controller 35 receives a command request from aninduction heating apparatus 10, according to the command request, theswitching controller 35 controls switching of the output switch 31 forthe first power source, the output switch 32 for the second powersource, and the high-frequency input switch 33 and the low-frequencyinput switch 34 connected to the induction heating apparatus 10 havingoutput the command request. If the switching control is completed, theswitching controller 35 outputs a switching completion signal to thecorresponding induction heating apparatus 10. Then, upon receipt of theswitching completion signal from the switching controller 35, thecorresponding induction heating apparatus 10 controls the first powersource 21 and the second power source 26 by the heater controller 14.

This merely shows one sequence control process, and may be changed asfollows. In other words, if the switching controller 35 receives acommand request from an induction heating apparatus 10, according to thecommand request, the switching controller 35 controls switching of theoutput switch 31 for the first power source, the output switch 32 forthe second power source, and the high-frequency input switch 33 and thelow-frequency input switch 34 connected to the induction heatingapparatus 10 having output the command request. Then, if the switchingcontrol is completed, the switching controller 35 controls the output ofat least one of the first power source 21 and the second power source 26in accordance with the output control information received together withthe command request from the corresponding induction heating apparatus10.

In this way, according to the induction heating system 1 shown in FIG.1, it is possible to perform various heat treatments by selecting one ofthe following four modes.

In a first mode, the induction heating apparatus receives supply ofelectric power of one frequency, that is, the high frequency from thefirst power source 21.

In a second mode, the induction heating apparatus receives supply ofelectric power from the second power source 26.

In a third mode, the induction heating apparatus receives supply ofelectric power of different frequencies from the first power source 21by the time-division method.

In a fourth switching mode, the induction heating apparatus receivessupply of electric power having one frequency from the first powersource 21 and electric power from the second power source 26 in asuperimposed manner.

Therefore, according to the induction heating system 1 shown in FIG. 1,it is possible to perform a heat treatment having the frequency effect.

Although the method of sequentially heating a plurality of workpieces bythe induction heating system 1 has been described, the induction heatingsystem 1 shown in FIG. 1 can also supply electric power from the powersource system 20 to two or more induction heating apparatuses 10 whichare electrically symmetric, at the same time. In this case, theswitching controller 35 needs to switch on the high-frequency inputswitches 33 and the low-frequency input switches 34 connected to theinduction heating apparatuses 10 to receive simultaneous power supply.Others may be appropriately changed on the basis of the sequences ofFIGS. 13 and 14.

Also, the induction heating system 1 is very versatile, and can be usedaccording to heat treatments on workpieces. For example, the inductionheating system 1 can be used to perform quenching by an inductionheating apparatus 10 and perform tempering by another induction heatingapparatus 10.

Supply from One Power Source System to Multiple Induction HeatingApparatuses

FIG. 15 is a time chart illustrating how many induction heatingapparatuses one power source system can supply electric power to. InFIG. 15, (a) shows a case of using two induction heating apparatuses,(b) shows a case of using three induction heating apparatuses, and (c)shows a case of using five induction heating apparatuses. A cycle timeis denoted by τ. Also, the time chart is on the premise that one powersource system 20 is used to perform the same heat treatment by aplurality of induction heating apparatuses 10. The time chart isapplicable even to power supply of both of the superimposing method andthe time-division method.

In FIG. 15, “SWITCHING” means a process of switching on or off theoutput switch 31 for the first power source, the output switch 32 forthe second power source, the high-frequency input switches 33 and thelow-frequency input switches 34 of each induction heating apparatus 10in the induction heating system 1 shown in FIG. 1.

In FIG. 15, “HEATING” means a process of supplying electric power fromthe power source system, that is, from one or both of the first powersource 21 and the second power source 26, to one of the inductionheating apparatuses 10 and heating a workpiece by the heating coil 13 ofthe induction heating apparatus 10 in the induction heating system 1shown in FIG. 1.

In FIG. 15, the term “COOLING” means a process of cooling the workpieceby spraying the quenching liquid or the cooling liquid onto theworkpiece in the induction heating system 1 shown in FIG. 1.

In FIG. 15, the term “RELEASING & HOLDING” means a process of removing aworkpiece having been subjected to an induction heating process, from aworkpiece supporting means (not shown) and putting the next workpiece onthe workpiece supporting means in the induction heating system 1 shownin FIG. 1.

Each induction heating apparatus 10 repeats a switching process, aheating process, a cooling process, and an attaching/detaching processin this order. A switching time, a heating time, a cooling time, and anattaching/detaching time are denoted by Ta, Tb, Tc, and Td,respectively. In a case of using n-number of induction heatingapparatuses 10, the heating time and the cooling time are denoted by Tbnand Ten, respectively. Also, the switching time Ta and theattaching/detaching time Td are set to values independent from thenumber of induction heating apparatuses. The cycle time τ and theindividual times Ta, Tb, Tc, and Td have the following relation:

τ=Ta+Tb+Tc+Td

In the induction heating system 1, in a case of using two inductionheating apparatuses 10, as shown in (a) of FIG. 15, a switching processon the first induction heating apparatus 10A is performed, and then thefirst induction heating apparatus 10A performs a heating process. If theheating process terminates, another switching process starts, and thefirst induction heating apparatus 10A immediately starts a coolingprocess; whereas the second induction heating apparatus 10B waits forthe completion of the another switching process and performs a heatingprocess. If a cooling time Tc2 elapses from the start of the coolingprocess of the first induction heating apparatus 10A, the firstinduction heating apparatus 10A performs an attaching/detaching process,whereas the second induction heating apparatus 10B continues the heatingprocess. If a heating time Tb2 elapses from the start of the heatingprocess of the second induction heating apparatus 10B, another switchingprocess is performed, and the second induction heating apparatus 10Bimmediately starts a cooling process; whereas the first inductionheating apparatus 10A waits for the completion of the another switchingprocess and performs another heating process. Then, the first inductionheating apparatus 10A sequentially repeats the same processes; whereasthe second induction heating apparatus 10B, if a cooling time Tc2elapses, an attaching/detaching process is performed, and then the sameprocesses are sequentially repeated.

Here, in a case of operating three induction heating apparatus 10 in thesame cycle time τ in the induction heating system 1, since it isdifficult to reduce the switching time Ta and the attaching/detachingtime Td, as shown in (b) of FIG. 15, the heating time Tb and the coolingtime Tc are set to be different from those in the case of using twoinduction heating apparatuses 10.

Further, in a case of operating n-number of induction heatingapparatuses in the same cycle time τ in the induction heating system 1(here, n is an integer of 2 or greater), as shown in (c) of FIG. 15,each of the heating time Tbn and the cooling time Ten is obtained, andan induction heating condition according to the obtained heating timeTbn, and a cooling condition according to the cooling time Ten are set.

As described above, in a case of using one power source system tooperate a plurality of induction heating apparatuses 10 in the cycletime τ, a period during the power source system 20 can be connected toeach induction heating apparatus 10 to supply electric power to thecorresponding induction heating apparatus 10, that is, a heating time isobtained, and duty ratio, frequency selection, and electric power ofeach frequency, and the like are set so as to fulfill certain conditionsin accordance with the heating time obtained for each induction heatingapparatus 10.

Setting of Control from Induction Heating Apparatus

A method of setting heating conditions from each induction heatingapparatus 10 to the system control unit including the switchingcontroller 35 in the induction heating system 1 shown in FIG. 1 will bedescribed.

FIGS. 16A to 16D are views illustrating examples of condition settingscreens which are used in a case of setting heating conditions from eachinduction heating apparatus to the system control unit including theswitching controller. More specifically, FIG. 16A shows an example ofcondition settings of steps, FIG. 16B shows a first set table of thetime-division method, FIG. 16C shows a second set table of thetime-division method, and FIG. 16D is a first set table of thesuperimposing method.

In the table shown in FIG. 16A, the first column represents the order ofsteps, and in the first row, an item ‘STEP’ represents the number ofeach step, an item ‘TIMER’ represents time, an item ‘ROTATE’ representsthe rotation speed of a workpiece, an item ‘HSWTABLE’ represents thetable reference destination information of the time-division method, anitem ‘HSW2VR’ represents an output intensity, an item ‘HSW2DT’represents the output ratio of the high frequency and the low frequency,an item ‘BADTABLE’ represents the table reference destinationinformation of the superimposing method, an item ‘2BNDVR’ represents theoutput intensity of the second power source 26, and an item ‘2BNDFREQ’represents information relative to the frequency of the second powersource 26.

As shown in FIG. 16A, for each step, a time is set to the item ‘TIMER’,and the rotation speed of a workpiece is set to the item ‘ROTATE’.

In a case of using the time-division method, information on a set tabledestination to be referred to in a case of performing table heating isset, and when step heating is performed, an output intensity VR, and theduty ratio DT of the low frequency are set as shown in FIG. 16A.

In a case of using the superimposing method, information on a set tabledestination to be referred to in a case of performing table heating isset, and when step heating is performed, an output intensity VR and afrequency are set. Here, setting a frequency means setting a frequencyto be output on the premise on a case where it is possible to set afrequency to be output by the second power source 26.

Here, the step heating means a method in which a heat signal and heatingconditions having the output intensity VR and the duty ratio DT of thelow frequency as items are sent from each induction heating apparatus tothe power source system 20 through the switching controller 35 for eachstep, and if each of the first power source 21 and the second powersource 26 receives the heat signal and the heating conditions, thecorresponding power source performs output control to heat a workpiece.

On the other hand, the table heating means a method in which tables asshown in FIGS. 16B to 16D are sent from each induction heating apparatusto the power source system 20 through the switching controller 35 inadvance, and each of the first power source 21 and the second powersource 26 performs output control according to the tables, so as to heata workpiece.

If the step heating is used, in each step, a signal is sent from eachinduction heating apparatus to each power source to control start andtermination of heating. Therefore, due to transmission and reception ofthe signal, an error occurs in the heating time. In contrast, if thetable heating is used, a heating start signal and a heating terminationsignal are not sent or received with respect to each induction heatingapparatus for each heating operation. Therefore, it is possible toaccurately control the heating time. In the table heating, even in acase of changing the heating condition in time series within one table,it is possible to accurately control the heating time under each heatingcondition. In other words, if the table heating is used, since theheating condition is sent to each power source in advance, it ispossible to increase the accuracy of the heating time, and even if theheating condition changes, it is possible to accurately perform outputin the heating time of each heating condition.

In each step of FIG. 16A, if the item ‘HSWTABLE’ is 0, the first powersource 21 does not perform the table heating, and if an item ‘2BNDTABLE’is 0, the first power source 21 and the second power source 26 do notperform the table heating. Meanwhile, if the item ‘HSWTABLE’ is 1, thefirst set table of the time-division method shown in FIG. 16B isreferred to, and if the item ‘HSWTABLE’ is 2, the second set table ofthe time-division method shown in FIG. 16C is referred to, and if theitem ‘2BNDTABLE’ is 1, the first set table of the superimposing methodshown in FIG. 16D is referred to.

In FIGS. 16B and 16C, reference symbols ‘VR’, ‘DT’, and ‘HT’ representthe output intensity, the duty ratio of the low frequency, and theheating time, respectively, and in FIG. 16D, reference symbols ‘VR’,‘FRQ’, and ‘HT’ represent the output intensity, the output frequency,and the heating time, respectively.

In this way, a heating condition is set from each induction heatingapparatus 10 to the system control unit including the switchingcontroller 35.

Setting for Output Monitoring

How to monitor output in a case of setting conditions like those in eachtable shown in FIGS. 16A to 16D will be described. FIG. 17 is a viewillustrating an example of an output monitoring screen.

In FIGS. 16A to 16D, power supply is performed in STEP 3, STEP 5, andSTEP 7. Therefore, output monitoring steps are denoted by 3, 5, and 7which are the numbers of STEP 3, STEP 5, and STEP 7. In each of STEP 3,STEP 5, and STEP 7, an item ‘TABLE MONITORING ROW’ represents a row formonitoring in a table for reference. For example, in STEP 3, since theitem ‘HSWTABLE’ is 1 in the table of FIG. 16A, the table of FIG. 16B isreferred to, and a row for monitoring in the table of FIG. 16B is set tothe item ‘TABLE MONITORING ROW’. An item ‘MONITORING MASKING TIME’ meansa time for which monitoring is not performed after heating starts, andif an item ‘MONITORING AT THE END ONLY’ is ‘YES’, monitoring isperformed for a value at the end of the heating. In

FIG. 17, for each of the time-division method and the superimposingmethod, electric power P1 and P2, the DC current Idc and the DC voltageVdc which are input from the converter 21 a or 26 a to the inverter 21 bor 26 b, and frequencies F1 and F2 are set. With respect to eachparameter, an upper limit and a lower limit are set, and a measuredvalue is displayed.

However, the power source controllers 21 x and 26 x of the first powersource 21 and the second power source 26 perform control such that theDC voltage becomes constant, or such that the DC current becomesconstant. To this end, the output situation of each power source ismonitored as a control object. In other words, each of the power sourcecontrollers 21 x and 26 x monitors the DC voltage Vdc for control tomake the DC voltage constant, and monitors the DC current Idc forcontrol to make the DC current constant.

Therefore, in the time-division method, the frequencies and any one ofthe DC voltage Vdc and the DC current Idc which are control objects arecontinuously monitored, and the value of electric power during heatingtermination is monitored. Meanwhile, in the superimposing method, thefrequencies and any one of the DC voltage Vdc and the DC current Idcwhich are control objects are continuously monitored, and the value ofelectric power during heating termination is monitored. Also, in a casewhere the item ‘MONITORING AT THE END ONLY’ is ‘YES’ in FIG. 17, allvalues at the end of the heating operations are monitored.

Now, a monitoring method will be described.

In a case of using the table heating, there is a monitoring method asfollows.

As a first process, on a monitoring screen as shown in FIG. 17, eachvalue is set.

As a second process, a step of condition setting of which table heatingwill be monitored, and a row for monitoring of 15 rows of a table to bemonitored are set. FIG. 17 shows a case where it is possible to setthree rows as rows of table heating to be monitored.

As a third process, an inverter table operation measurement data deviceis always read, whereby a corresponding table row is monitored. Here,the inverter table operation measurement data device is a measuring unitto be described below. With respect to electric power, as will bedescribed below, average electric power is monitored by reading a valueduring heating termination.

Also, even in a case of using the step heating, that is, even if theoutput intensity VR, the duty ratio DT of the low frequency, and thefrequency of a step are input, each value is set on the monitoringscreen, a step of condition setting of which step heating will bemonitored is set, and the inverter table operation measurement datadevice is constantly read, thereby monitoring the DC voltage Vdc, the DCcurrent Idc, electric power during heating termination, the frequency ofthe step set as a monitored object.

Equipment for Monitoring Electric Power How to monitor electric powerwill be described in detail with reference to the circuits shown inFIGS. 3 and 4. As shown in FIGS. 3 and 4, the converter 21 a and theinverter 21 b are controlled by the inverter control units 21 c, and theconverter 26 a and the inverter 26 b are controlled by the invertercontrol unit 26 c. Therefore, the DC current Idc and the DC voltage Vdcapplied from the converter 21 a to the inverter 21 b or from theconverter 26 a to the inverter 26 b are measured by a current sensor 101and a voltage sensor 102 shown in FIGS. 3 and 4, and the measured valuesare input to a measuring section 103. The values input to the measuringsection 103 are converted into digital values, which are output to aprocessing unit 104. The measuring section 103 is provided for each ofthe first power source 21 and the second power source 26, and theprocessing unit 104 is provided in each induction heating apparatus 10or in a managing unit (not shown) for generally controlling theinduction heating system 1.

There are various methods of monitoring electric power during operationof the induction heating system 1. Hereinafter, a case of supplyingelectric power according to a DT signal by the time-division method willbe described.

FIG. 18 is a view for explaining a first output monitoring method, andthe vertical axis represents time, and the vertical axis represents theDC voltage Vdc, the DC current Idc, and the duty ratio DT of the lowfrequency. In a first output monitoring method, when the DT signal is inan ON state, that is, when the low frequency is being output,instantaneous values v_(dc) and i_(dc) are detected by the currentsensor 101 and the voltage sensor 102. Therefore, low-frequency electricpower and high-frequency electric power are obtained from the followingequations.

The low-frequency electric power P1 (kW) is as follows:

P1=v _(dc)(V)×i _(dc)(A)×DT(%)×10⁻²×10⁻³

The high-frequency electric power P2 (kW) is as follows:

P2=v _(dc)(V)×i _(dc)(A)×(100−DT(%))×10⁻²×10⁻³

In the first output monitoring method, the instantaneous value v_(dc) isrelatively stable, and thus the DC current Idc changes at the duty ratioDT of the low frequency as time goes on. The reason is that in thetime-division method, output is performed according to the controlmethod of each power source, for example, such that the DC voltagebecomes constant, and thus the current changes according to a change inload impedance. For this reason, accurate monitoring is impossible.

In the present invention, in a second monitoring method, for eachpredetermined interval Δt (for example, 0.5 ms), the instantaneousvalues v_(dc) and i_(dc) are detected by the current sensor 101 and thevoltage sensor 102. Next, the product of the instantaneous values v_(dc)and i_(dc), that is, the products of the instantaneous values of the DCvoltages and the DC currents at each sampling time are obtained, and areintegrated for each of the low frequency and the high frequency for eachstep heating period, whereby electric power during step termination isobtained.

FIG. 19 is a view for explaining the second output monitoring method. InFIG. 19, (a) shows changes of the DC voltage and the DC current withtime, and (b) to (e) show changes of the DT signal, integrallow-frequency power consumption, integral high-frequency powerconsumption, and the heat signal with time, respectively.

As shown in (a) of FIG. 19, since the DC voltage and the DC currentchange as time goes on, at each sampling time, for example, at theintervals of 0.5 ms, instantaneous values are detected by the currentsensor 101 and the voltage sensor 102. Then, for each sampling time, theintegrated value q (J) of electric power with respect to time isobtained by the following equation.

q(J)=v _(dc)(V)×i _(dc)(A)×[SAMPLEING TIME(s)]A

Next, the sum QL (J) of the products of low-frequency electric power andtime, and the sum QH (J) of the products of high-frequency electricpower and time are obtained by the following equations, respectively.

QL(J)=Σq(J)

(Here, the integration is performed for a period when the DT signal isat a high level (a low frequency output period))

QH(J)=Σq(J)

(Here, the integration is performed for a period when the DT signal isat a low level (a high frequency output period))

Then, average low-frequency electric power P1 (kJ/s) and averagehigh-frequency electric power P2 are obtained by the followingequations. Here, HT (s) represents a total heating time.

P1(kJ/s=kW)=QL(J)/HT(s)×10⁻³

P2(kJ/s=kW)=QH(J)/HT(s)×10⁻³

In the induction heating system 1 according to the embodiment of thepresent invention, an output monitoring apparatus 110 is connected tothe first power source 21 and the second power source 26 of a powersupply apparatus 120 serving the power source system shown in FIGS. 3and 4, via wirings. FIG. 20 is a block diagram schematicallyillustrating an output monitoring apparatus 110. The output monitoringapparatus 110 includes the measuring section 103 and the processing unit104.

The measuring section 103 measures the DC current Idc and the DC voltageVdc which are output from the converter 21 a to the inverter 21 b orfrom the converter 26 a to the inverter 26 b shown in FIGS. 3 and 4, ateach sampling time.

The processing unit 104 obtains an amount of electric power for eachfrequency from the values of the currents and the voltages measured atthe individual sampling times by the measuring section 103, and obtainsaverage electric power of each frequency on the basis of the amount ofelectric power of the corresponding frequency.

The power supply apparatus 120 is configured to be attached to theplurality of induction heating apparatuses 10 through the switchingsection 30, and be connectable to one of the induction heatingapparatuses 10 by control of the plurality of induction heatingapparatuses 10 on the switching section 30. In a case where the powersupply apparatus 120 is configured like that, the processing unit 104 isprovided to each of the plurality of induction heating apparatuses 10.Therefore, it is possible to acquire measurement data of the measuringsection 103 with respect to the power supply apparatus 120, and eachprocessing unit 104 determines the consistency of the average electricpower of each frequency and a supply command having been issued to thepower supply apparatus 120.

As shown in FIG. 20, the measuring section 103 includes a current andvoltage measuring unit 103 a and a frequency measuring unit 103 b tocorresponding to a method in which the power supply apparatus 120supplies electric power in a time-division manner. In other words, thecurrent and voltage measuring unit 103 a measures the DC current and theDC voltage which are output from the converter 21 a to the inverter 21 bor from the converter 26 a to the inverter 26 b, from detection valueswhich are input from the current sensor 101 and the voltage sensor 102shown in FIGS. 3 and 4, at each sampling time. The frequency measuringunit 103 b counts the number of times of switching made by the inverter21 b or 26 b per unit time, thereby measuring the frequency of theoutput voltage or current.

Therefore, the processing unit 104 obtains an amount of electric powerof each frequency obtained by the frequency measuring unit 103 b, fromthe values of the current and the voltage measured at each sampling timeby the current and voltage measuring unit 103 a, and obtains the averageelectric power of the corresponding frequency on the basis of the amountof electric power of the corresponding frequency.

Output Monitoring Method

A method of monitoring output using the output monitoring apparatus 110shown in FIG. 20 will be described.

As shown in FIG. 3, when a direct current is output while being switchedon and off at a first frequency (for example, a low frequency) and asecond frequency (for example, a high frequency) by the inverter 21 b,first, the current and voltage measuring unit 103 a measures the DCcurrent and the DC voltage at each of sampling times, from detectiondata input from the current sensor 101 and the voltage sensor 102.

Next, when the inverter 21 b switches on and off the direct current atthe first frequency, the processing unit 104 receives the currents andthe voltages measured at the individual sampling times by the currentand voltage measuring unit 103 a. The processing unit 104 adds theproducts of the input values, that is, the currents and the voltages ofthe individual sampling times, and divides the sum by the inductionheating time which is the output time, thereby obtaining average outputpower of the first frequency. Also, when the inverter 21 b switches onand off the direct current at the second frequency, the processing unit104 receives the currents and the voltages measured at each of samplingtimes by the current and voltage measuring unit 103 a. The processingunit 104 multiplies the input values, that is, the current and thevoltage of each sampling time, adds the values of the individualsampling times obtained by the multiplication, and divides the sum bythe induction heating time which is the output time, thereby obtainingaverage output power of the second frequency.

Next, the processing unit 104 may display the supplied electric power ona display unit (not shown) on the basis of the value of the averageoutput power of the first frequency and the value of the average outputpower of the second frequency, thereby making a superintendent monitorthe supplied electric power. It is monitored whether the average outputpower of each of the first frequency and the second frequency is betweenthe upper limit and the lower limit set by the processing unit 104, andin a case where the average output power of each of the first frequencyand the second frequency is out of the range between the upper limit andthe lower limit, a stop signal is output to stop the output. Like this,in a case where a threshold value or an allowable range is set for eachfrequency, if the average output power of the corresponding frequencyexceeds the threshold value or is out of the allowable range, it ispossible to stop the output and remove any workpiece having not beensubjected to appropriate induction heating.

As described above, the output monitoring apparatus 110 obtains averageelectric power of each frequency by sampling the DC voltage Vdc and theDC current Idc at predetermined intervals over the entire heating time.Therefore, it is possible to monitor changes such as rising of theoutput. In other words, it is possible to reduce the heating time, andto monitor even the transition state of rising of the output.

In the output monitoring method according to the embodiment of thepresent invention, the integral low-frequency power consumption isdivided by the total heating time, whereby the average electric power ofthe low frequency is obtained, and the integral high-frequency powerconsumption is divided by the total heating time, whereby the averageelectric power of the high frequency is obtained.

Therefore, the processing unit 104 can monitor an anomaly of the DTsignal designating switching between the first frequency and the secondfrequency, on the basis of changes in the magnitudes of the averageelectric power of the first frequency and the average electric power ofthe second frequency.

If an anomaly occurs in the DT signal to cause changes in the outputtimes of the first frequency and the output times of the secondfrequency, integral electric power consumption of the output period ofthe first frequency and integral electric power consumption of theoutput period of the second frequency also change. As a result, theaverage electric power of each frequency obtained by dividing theintegral electric power consumption of the corresponding frequency bythe total output time also changes. Therefore, if it is monitoredwhether the values of the average electric power of the first frequencyand the value of the average electric power of the second frequencychange in time series, it is possible to monitor an anomaly of theso-called DT signal designating switching between the first frequencyand the second frequency. Like this, if the average electric power ofeach frequency is monitored, it is possible to monitor even the DTsignal.

Now, output monitoring in the case of using the superimposing methodwill be described. In the system shown in FIG. 1, the product of the DCvoltage and the DC current is obtained for each of the first powersource 21 and the second power source 26, and the integrated value ofthe products is divided by the total heating time, thereby obtainingaverage electric power. Then, it is possible to monitor the output in away similar to that in the case of using the time-division method.

Modification of Output Monitoring Method

The above-mentioned output monitoring method is for the case whereelectric power is supplied by the time-division method. However, thismethod can also be applied to a case where a low frequency and a highfrequency are alternately output in a short time by the superimposingmethod. This will be described below in detail. FIG. 21 is a viewillustrating existence or non-existence of output of the first frequencyand existence or non-existence of output of the second frequency in timeseries in a case where electric power is supplied by the superimposingmethod.

The circuit configuration using the superimposing method shown in FIG. 4is on the premise on a case of alternately outputting a signal output byswitching on and off the direct current at the first frequency by theinverter 21 b and a signal output by switching on and off the directcurrent at the second frequency by the inverter 26 b, as shown in FIG.21. First, each measuring section 103 shown in FIG. 4 receives input ofdetection signals from the current sensor 101 and the voltage sensor102, and measures the DC current and the DC voltage at each of samplingtimes.

Next, when the inverter 21 b switches on or off the direct current atthe first frequency, the processing unit 104 receives the currents andthe voltages sampled by the current and voltage measuring unit 103 a.The processing unit 104 integrates the products of the input values,that is, the current and voltage values of the individual samplingtimes, and divides the integrated value by the output time, therebyobtaining the average output power of the first frequency. Also, whenthe inverter 26 b switches on and off the direct current at the secondfrequency, the processing unit 104 receives the currents and thevoltages sampled by the current and voltage measuring unit 103 a. Theprocessing unit 104 integrates the products of the input values, thatis, the current and voltage values of the individual sampling times, anddivides the integrated value by the output time, thereby obtaining theaverage output power of the second frequency.

Next, the processing unit 104 may display the supplied electric power ona display unit (not shown) on the basis of the magnitudes of the averageoutput power of the first frequency and the average output power of thesecond frequency, thereby making a superintendent monitor the suppliedelectric power.

As described above, in the embodiment of the present invention, themeasuring sections 103 measure the DC voltages and the DC currents whichare output from the converters 21 a and 26 a to the inverters 21 b and26 b in the first power source 21 and the second power source 26 formingthe power source system 20, at each sampling time. Therefore, it ispossible to monitor electric power which is output from the first powersource 21 and the second power source 26, and the like.

Monitoring of Power Supply to One Induction Heating Apparatus

Until now, the case where one of the induction heating apparatuses 10 isconnected to the power source system 20 through the switching section 30and electric power is supplied from the power source system 20 to thecorresponding induction heating apparatus 10 has been mainly described.However, even in a case where there is only one induction heatingapparatus 10 and electric power is supplied to the induction heatingapparatus 10, output monitoring can be similarly performed.

That is, assuming that the induction heating system 1 of FIG. 1 has onlythe induction heating apparatus 10A, output monitoring is performed asfollows. The induction heating system 1 has at least one of the firstpower source 21 and the second power source 26, as at least one powersupply apparatus 120. As shown in FIGS. 3 and 4, the first power source21 includes the converter 21 a configured to convert an alternatecurrent into a direct current, and an inverter 21 b for converting thedirect current input from the converter 21 a by switching on and off thedirect current at an optional frequency, and outputting the convertedsignal. As shown in FIG. 4, the second power source 26 includes theconverter 26 a configured to convert an alternate current into a directcurrent, and an inverter 26 b configured to convert the direct currentinput from the converter 26 a by switching on and off the direct currentat an optional frequency, and outputting the converted signal. The powersupply apparatus 120 is connected to supply electric power to a singleheating coil 13 as shown in FIGS. 3 and 4. If there is a plurality ofheat treatment areas in one workpiece, a plurality of coils may beconnected in series or in parallel. Even in this case, the term “singleheating coil 13” is used as the collective name of the plurality ofcoils. One heating coil corresponds to one workpiece, and the oneheating coil is called a single heating coil.

This induction heating system 1 is equipped with output monitoringapparatuses 110 each of which includes the measuring section 103 and theprocessing unit 104 shown in FIG. 20. The measuring sections 103 measurethe DC voltages and the DC currents which are output from the converters21 a and 26 a to the inverters 21 b and 26 b, at each sampling time.Each measuring section 103 includes the current and voltage measuringunit 103 a and the frequency measuring unit 103 b as described withreference to FIG. 20. Each processing unit 104 obtains an amount ofelectric power of a corresponding frequency, from the values of thecurrents and the voltages of the individual sampling times measured bythe measuring section 103, and obtains average electric power of thecorresponding frequency on the basis of the amount of electric power ofthe corresponding frequency.

When this induction heating system 1 is used to switching on or off atleast on direct current at at least one frequency, thereby performinginduction heating, the currents and the voltages where are output fromthe converters 21 a and 26 a to the inverters 21 b and 26 b in the firstpower source 21 and the second power source 26 are measured at eachsampling time, and the products of the currents and the voltagesmeasured at the sampling times are integrated with respect to eachfrequency, whereby the average electric power of each frequency isobtained. As a result, it is possible to monitor the output situation ofthe power supply apparatus 120 on the basis of the average electricpower of each frequency.

In a case where the power supply apparatus 120 supplies electric powerby the time-division method, output monitoring is performed as follows.As the power supply apparatus 120, the first power source 21 is providedas shown in FIG. 3. In a case where the inverter 21 b of the first powersource 21 adjusts the output power of the high frequency and the outputpower of the low frequency at the ratios of the high frequency outputtime and the low frequency output time with respect to the outputperiod, specifically, in a case where the inverter 21 b of the firstpower source 21 alternatively outputs the low frequency and the highfrequency, the processing unit 104 calculates the products of the DCcurrents and the DC voltages of the individual sampling times measuredon the basis of the input values from the current sensor 101 and thevoltage sensor 102 by the measuring section 103, thereby obtaining theaverage electric power of the high frequency and the average electricpower of the low frequency supplied from the first power source 21serving as one power supply apparatus 120 to the heating coil 13.

That is, when one direct current is switched on or off differently atthe high frequency (the first frequency) and at the low frequency (thesecond frequency) by the DT signal, and the high frequency and the lowfrequency are output by time-division multiplexing for performinginduction heating, the current and voltage of the one direct current ismeasured at each sampling time. The products of the currents and thevoltages of the individual sampling times measured during the switchingat the first frequency are integrated, whereby the average electricpower of the first frequency is obtained. Similarly, the products of thecurrents and the voltages of the individual sampling times measuredduring the switching at the second frequency are integrated, whereby theaverage electric power of the second frequency is obtained. On the basisof the average electric power of the first frequency and the averageelectric power of the second frequency, it is possible to monitoringoutput power.

In a case where the power supply apparatus 120 supplies electric powerby the superimposing method, output monitoring is performed as follows.As shown in FIG. 4, the power supply apparatus 120 includes the firstpower source 21 serving as a first power supply apparatus, and thesecond power source 26 serving as a second power supply apparatus. Inthis case, in the first power source 21, the inverter 21 b converts thedirect current input from the converter 21 a by switching on and off thedirect current at the first frequency, and outputs the converted signal.Simultaneously with this, in the second power source 26, the inverter 26b converts the direct current input from the converter 26 a by switchingon and off the direct current at the second frequency, and outputs theconverted signal. The first frequency and the second frequency from thetwo power sources of the first power source 21 and the second powersource 26 are superimposed and supplied to the heating coil 13.

In this case, as shown in FIG. 4, the measuring section 103 includes afirst measuring unit 103 c that is provided for the first power source21, and a second measuring unit 103 d that is provided for the secondpower source 26. The first measuring unit 103 c measures the DC currentand the DC voltage output from the converter 21 a to the inverter 21 bin the first power source 21, at each sampling time. The secondmeasuring unit 103 d measures the DC current and the DC voltage outputfrom the converter 26 a to the inverter 26 b in the second power source26, at each sampling time.

Accordingly, the processing unit 104 obtains the amount of electricpower of the first frequency from the values of the currents and thevoltages of the individual sampling times measured by the firstmeasuring unit 103 c, obtains the amount of electric power of the secondfrequency from the values of the current and the voltage of theindividual sampling times measured by the second measuring unit 103 d,and obtains the average electric power of the first frequency and theaverage electric power of the second frequency on the basis of theamount of electric power of the first frequency and the amount ofelectric power of the second frequency.

In other words, in a case where the first power source 21 converts afirst direct current by switching on and off the first direct current atthe first frequency and outputs the converted signal while the secondpower source 26 converts a second direct current by switching on and offthe second direct current at the second frequency, and the firstfrequency and the second frequency are superimposed to perform inductionheating, the first measuring unit 103 c measures the current and voltageof the first direct current at each sampling time, and the secondmeasuring unit 103 d measures the current and voltage of the seconddirect current at each sampling time. Then, the processing unit 104integrates the products of the currents and voltages of the individualsampling times relative to the first direct current and measured duringthe switching at the first frequency, and divides the integrated valueby the induction heating time, thereby obtaining the average electricpower of the first frequency. Similarly, the processing unit 104integrates the products of the currents and voltages of the individualsampling times relative to the second direct current and measured duringthe switching at the second frequency, and divides the integrated valueby the induction heating time, thereby obtaining the average electricpower of the second frequency. On the basis of the average electricpower of the first frequency and the average electric power of thesecond frequency, the processing unit 104 monitors the output power.

The case where the induction heating system 1 includes a plurality ofinduction heating apparatuses as shown in FIG. 1 has been alreadydescribed, and thus is described here.

As described above, in the induction heating system 1, the suppliedelectric power is monitored by the output monitoring apparatus 110.Therefore, it is possible to monitor an anomaly of a load, an anomaly ofa bus bar, and the like.

Other Monitoring

Since the induction heating system 1 shown in FIG. 1 includes the outputmonitoring apparatus 110, it is possible to monitor electric powersupplied to each induction heating apparatus 10. The output monitoringapparatus 110 can also be used to monitor an actual output frequency andthe DC voltage Vdc during heating for a very short time.

For example, in the output monitoring apparatus 110, the current andvoltage measuring unit 103 a can measure the DC voltage Vdc input to theinverter 21 b or 26 b at each sampling time, thereby always monitoringthe DC voltage Vdc. In this case, it is possible to obtain the averagevalue of a plurality of data items every sampling time, for example, 4ms to 6 ms in disregard of several milliseconds immediately afterswitching to a frequency, and integrate the average values of theindividual sampling times until termination of the correspondingfrequency, and dividing the integrated value by the number of samplingtimes, thereby monitoring the average DC voltage.

For example, in the output monitoring apparatus 110, the frequencymeasuring unit 103 b can monitor the number of times of switching perunit time by the inverter 21 b or 26 b, thereby measuring the frequency.Therefore, while electric power of each frequency is being output, it ispossible to monitor the output frequency.

For example, even in heating for a very short time, it is possible tomeasure the DC voltage Vdc and the frequency, thereby monitoring them.

Like this, even when electric power is being supplied, it is possible toalways monitor the DC voltage and the frequency as control objects, andit is possible to provide a guidance representing whether inductionheating is being appropriately performed.

While the present invention has been described in connection withcertain embodiments thereof, those skilled in the art will understandthat various changes and modifications may be made within the scope ofthe invention as defined by the appended claims.

INDUSTRIAL APPLICABILITY

One or more embodiments of the invention provide an induction heatingsystem and an induction heating method for supplying electric power withdifferent frequencies to a plurality of induction heating apparatuses,an output monitoring apparatus and an output monitoring method formonitoring an output situation when electric power is supplied from apower supply apparatus to a heating coil to perform induction heating,and an induction heating apparatus having a low-frequency currenttransformer and a high-frequency current transformer.

This application is based on Japanese Patent Application Nos.2012-115121, 2012-115122 and 2012-115123, filed on May 18, 2012, theentire contents of which are incorporated herein by reference.

1. An induction heating method comprising: providing a plurality ofinduction heating apparatuses each having a heating coil, a first powersource configured to adjust a ratio of a high frequency output time anda low frequency output time with respect to an output period and tooutput a high-frequency electric power and a low frequency electricpower, a second power source configured to output an electric power of afrequency that is different from a frequency of the electric poweroutput from the first power source, and a switching section; operatingthe switching section from one of the induction heating apparatuses toselect one of a first mode, a second mode, a third mode, and a fourthmode; and induction heating a workpiece arranged on said one of theinduction heating apparatuses, wherein, in the first mode, said one ofthe induction heating apparatuses receives one of the high-frequencyelectric power and the low frequency electric power from the first powersource, wherein, in the second mode, said one of the induction heatingapparatuses receives the electric power from the second power source,wherein, in the third mode, said one of the induction heatingapparatuses receives electric power of different frequencies from thefirst power source by a time-division method; and wherein, in the fourthmode, said one of the induction heating apparatuses receives one of thehigh-frequency electric power and the low frequency electric power fromthe first power source and the electric power from the second powersource in a superimposed manner.